Air Amplifiers – Vent, Exhaust, Cool, Dry, Clean – With No Moving Parts!

As an Application Engineer, one of the interesting aspects of working with customers on applications is the varied types of solutions an EXAIR product can provide.  The Air Amplifier family – Super Air Amplifier, Adjustable Air Amplifier, and the special High Temperature Air Amplifier can be used in a wide variety of process and applications.  Below highlights several of those from past experiences.

A defense contractor was performing maintenance service on a Navy ship, and the ventilation system had to be shut down.  To keep the personnel cool and safe, an auxiliary ventilation was to be supplied.  Rather than use a cumbersome blower assembly, which has to mounted on the top deck, and ducted down to the lower decks, they chose to utilize (2) 4″ Super Air Amplifiers.  They are very portable and can be set up in minutes.  This solution provided the necessary air flow, providing a safe environment for the maintenance crew.

Super Air Amplifier

EXAIR Air Amplifiers use a small amount of compressed air to create a tremendous amount of air flow.

A light bulb manufacturer needed a better solution for a cooling operation.  During manufacturing of a mercury lamp, the bulb must be cooled from 700°C to 600°C in just 15 seconds.  The current method, an open brass pipe, was working but the noise level was too high (95 dBA.) The goal was to maintain the 15 second cooling time, but reduce sound levels to 85 dBA.  By utilizing (2) of 3/4″ Adjustable Air Amplifiers, the customer was able to maintain the cooling rate, and reduce the noise level down to 80 dBA, a 15 dBA reduction.

adjustable Air Amplifier

Adjustable Air Amplifier

A garbage collector presented a problem that needed a solution.  The garbage was incinerated and when the furnaces were first started up, there tended to be issues with getting the flue to draft properly.  Using the High Temperature Air Amplifier, the high velocity air flow and draw provided the needed draft until the stack warmed up and the natural draft would be established.  Since the unit is capable of handling temperatures up to 700°F, it was able to withstand the heat of the process after the compressed air was turned off.

These and other Applications for the Air Amplifiers and all other EXAIR products can be found on the EXAIR website on the Products page, under the Related Info section toward the bottom of each page.

If you have questions regarding Air Amplifiers or 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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Twitter: @EXAIR_BB

E-Vac Vacuum Generators- For More Than Just Pick and Place

A textbook application for vacuum generators is the ‘pick and place’ function.  With ever increasing automation and robotic cells, more and more opportunities present themselves to utilize the E-Vac Vacuum Generator as a part of the system to ‘pick up’ an object and ‘place’ it in a new position. But the E-Vac’s can be used for many more types of applications.

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In-Line E-Vac

Another popular usage is to hold something in place. One of our customers uses an array of Adjustable E-Vacs to pull a vacuum and hold down various sizes of Styrofoam sheets during a machining operation. The previous system was a 1 hp blower type, and did not offer any flexibility for handling different size sheets. Sheets would slip and produce off quality results. After installing the new design, the system was able to handle any size sheet, and scrap levels went down dramatically.

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Adjustable E-Vac

A unique implication that was solved with an E-Vac was to deflate sporting balls.  The customer printed custom logos, and preferred the items to be flat for the printing operation. Using a commercial grade electric shop vac didn’t completely deflate the balls, and motors burned out often.  Using a low vacuum In-Line E-Vac with a quiet Straight Through Muffler, the customer can now quickly and quietly, fully deflate the balls.

Another popular use for the E-Vac is to pull a vacuum for drawing up liquids or gases. A customer that manufactures automotive seats was having issues with the process, where the expanding foam was producing a gas, and the gas would produce pockets and voids in the foam after setting.  The customer used a model 800017 In-Line E-Vac to create a vacuum inside the mold and draw off the gas, eliminating the pockets and the voids in the final product.

Lastly, as I am big fan of recycling, anything and everything, we worked with a customer that recycles the old CRT style of computer monitor  (remember those?) The housing would be sawed in half, so that access to the internal components could be made. Because of the variability in the size and shape of the monitors, the customer was using an adjustable chuck system, which took time to set-up for every monitor, each being a bit different. To speed up the process, an EXAIR In-Line E-Vac and 5″ Suction Cup was implemented, and the monitor held in place by the screen, which was was very consistent in shape from monitor to monitor. This change reduced the set-up time required.

These and other Applications for the E-VACs and all other EXAIR products can be found on the EXAIR website on the Products page, under the Related Info section toward the bottom of each page.

If you have questions regarding E-Vac Vacuum Generators or 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
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Twitter: @EXAIR_BB

EXAIR Mini Chip Vac: Phase 2 for Improving Medical Devices

Medical Anatomy

In my previous blog about the manufacturing facility that machined small plastic components for the medical industry, I explained how the Stay Set Ion Air Jet Kit was able to improve the machining process by eliminating static.  (You can read the blog here: EXAIR Ion Air Jets: Phase 1 for improving medical devices).  With their machining center being in a semi-clean room, cleanliness was very important.  So, after each machining operation, they would have to sweep the plastic chips from the machining table and discard.  This extended the cycle time in their machining operation.

Since they had such a great relationship with EXAIR in dealing with their previous application, they contacted us again to improve their cleanup operation.  Non-conductive materials like plastic generates static on the surface when the material is peeled, shifted, or rubbed against another surface.  Since we removed the static from the plastic shavings with the Stay Set Ion Air Jet, we wanted to target that area before static could regenerate and start “sticking” to clean parts.  In getting more details about their setup, they were machining with vertical CNC mills.  The mills had a platform table that had a pneumatic fixture to grab the medical part.  Before machining began, the operators would have to close Plexiglas doors as a safety requirement.  The CNC mills did have an opening at the top of the machine.  (This was where they were supplying the Stay Set Ion Air Jet with compressed air and power supply.)

Mini Chip Vac

With my experience, I had a good suggestion for refining their cleaning operation.  I suggested the model 6193-5 Mini Chip Vac System.  This system uses compressed air to generate a vacuum for picking up chips.  The vacuum generator does not have any moving parts or bearings to wear; so, they are very durable and long-lasting.  The Mini Chip Vac System uses a 5 gallon drum which is very compact and easy to use in tight areas.  The system includes a 0.1 micron filter to keep all the contamination inside the drum and not allowing it to escape back into the room air.  (Very necessary in a semi-clean location.)  Even for its small size, the Mini Chip Vac is very powerful and quiet.  It has a decibel rating of only 77 dBA; so, noise will not be a nuisance when operating the vacuum.  It comes standard with a 10 foot vacuum hose which make it easy to reach into tight areas to clean.

As a suggestion, I recommended that they could collect the plastic shaving during the machining process Instead of waiting until after the operation to clean.  They could mount the Mini Chip Vac drum near the machine, and bring in the vacuum hose through the opening at the top.  The suction end of the vacuum could be placed on the opposite side of the Stay Set Ion Air Jet.  In conjunction, the Stay Set Ion Air Jet would remove the static and swarf from the plastic surface; at the same time, the Mini Chip Vac would collect and remove the plastic shavings from the machining area.  This combination of EXAIR products would keep the parts clean as well as the machining area.  When they installed the Mini Chip Vac System into their process, they almost doubled their production rate.

If you are dealing with messy chips in your machining operation, the EXAIR Chip Vac Systems can be a solution for you.  For the customer above, I was able to find a simple way to use the Mini Chip Vac to keep the area clean and increase their production rates.  If you are spending too much time in cleaning up your area, you can contact an Application Engineer to find the best solution to streamline your operation.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

 

Photo: Muscles Anatomy Medical Human by Heblo/64.  CC0 Public Domain

83% Cyle Time Improvement with EXAIR Super Air Amplifiers

EXAIR Super Air Amplifier – an easy way to quickly move large air volumes

 

At a shipyard in Finland, our distributor found an application using blowers which needed a more viable solution.  The application was to dry the interior of large tanks after coating, and the original solution was to use a blower mounted to a 12” opening on top of the tank.  The airflow from the blower was forced into the tank in an effort to dry the coating but often ended up without any drying effect at all.

This problem was due to vapors (non-combustible vapors) produced by the coating process which are more dense than the ambient air, causing them to collect on the bottom of the tank.  The airflow produced by the blower was not sufficient to force these vapors from the tank, causing a long drying cycle for the coating process or no drying at all.

But, these same tanks feature a 3” diameter plug in the bottom of the tank to allow for draining if needed.  And, this opening is almost perfectly sized for a 2” EXAIR Super Air Amplifier model 120022.  (Model 120022 has an outer diameter of 2.95” at the side which provides incoming ambient air.)  By removing the plug in the bottom of the tank and installing a 2” Super Air Amplifier, this tank can be fully dried in a fraction of the time required for an electric blower setup.  The end user estimated an 83% reduction in drying times (from one hour per tank to ~10 minutes), and gained confidence that the tanks would be 100% dry and free of vapor when using the EXAIR solution.

One additional benefit of this Super Air Amplifier solution was increased reliability.  The electrical supply to this shipyard is unstable, resulting in blackouts and surges which shut down electric blowers.  But because the Air Amplifiers do not rely on electricity and sufficient storage capacity was available for compressed air, these units are unaffected by electrical supply problems.

If you have a similar application or would like to discuss a problem currently present in your production facilities, contact an EXAIR Application Engineer.  We’re here to help.

Lee Evans
Application Engineer

LeeEvans@EXAIR.com
@EXAIR_LE

Reduce, Reuse, Recycle

I think we have all heard the mantra Reduce, Reuse, Recycle – a phrase that is thought to have originated back in 70’s when environmental protection became a governmental policy.

We at EXAIR can help your company follow this important principle and help to keep your costs down as well.

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Reduce – Reduce the number of times you change out your coolant, reduce your wastewater. Our Reversible Drum VAcs and Chip Trappers help keep your coolant clean by providing a simple and effective method to remove and/or strain your coolant.

Also, remember this – they are VERY hard to break or ruin. If you have one of our liquid handling Reversible Drum Vacs or Chip Trapper units, and the performance isn’t quite as you remember it to be, give us a call.   We can help to trouble shoot and narrow in on the root cause.  Most of the time, it is a simple fix, such as a air leak or a change to the air supply system that has caused a drop in performance. If we have eliminated all of those possible causes, we can offer the RDVREFURB option. Simply send in your Reversible Drum Vac pump unit, and we will do a free evaluation. Then we’ll let you know what we find, and provide a quote for the repair.  The repair typically involves a thorough cleaning, replacement of a few basic parts, and then setting and testing to original factory specification.  Because the unit has no moving parts, there isn’t much that can break down or go wrong.  Don’t throw away that unit, REDUCE the amount of waste you create.

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Reuse – Maybe you have a Super Air Knife in storage that is not in use, and you come up with a need, but the Knife doesn’t quite match the application.  We can provide new custom shim to change the air flow pattern.  Perhaps you have a 24″ Super Air Knife, but the new application requires only 18″ of airflow.  You can send the knife in and we can clean it up and install a new custom shim to provide the exact airflow pattern that meets your requirements.  Or, we can send the new shim directly to you for your team to install. Don’t let the unused product lie around, REUSE it for another process or application.

Super Air Knife

Recycle – If for what ever reason a product has been deemed to be no-longer viable and cannot be reused, the time comes to dispose of it.  We hope that you would take the time to recycle it properly. With materials of construction including brass, aluminum and type 303 and type 316 stainless steels, most EXAIR products can be RECYCLED as common metals and you may even get a little money back!

To discuss your processes and how an EXAIR Intelligent Compressed Air Product can provide a beneficial service, feel free to contact EXAIR and myself or one of our other Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

Send me an email
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Twitter: @EXAIR_BB

 

Photo Credit – “Recycling” by Andy Arthur is licensed under CC BY 2.0

Think Of Quality And Service, Think Of EXAIR

As an Application Engineer at a direct sales manufacturing company, I get to talk to a LOT of people about potential uses for our quiet, safe, and efficient compressed air products. And, I’m happy to say, most of them I can even help with…even if the answer is “that’s just not gonna work.” Those are few and far between, however, and we can usually point someone in a better direction in those cases.

By the time we’ve “drilled down” into an application discussion far enough to make a product recommendation, we’ve got a pretty good feeling about it, and a vast majority of the time, our product solves the application in a big way. So big, in fact, that it makes them think of EXAIR again, and again.

Case in point: not long after I started here in 2011, I had the pleasure of helping someone out with some pick-and-place rigs on their packaging line…small products, bulk packaged for shipment to retail outlets. They used our Model 810003M E-Vac High Vacuum Generator and 900762 Small Round Vacuum Cups. Over the years, they’ve added some new products, and some more of the E-Vac pick-and-place rigs. It’s always good to hear from them, and I really believe the feeling is mutual.

EXAIR E-Vac Vacuum Generators provide a simple and reliable solution to pick-and-place applications.

Now, they want to automate a little clean-up operation where pilot holes are drilled in a plastic part, and are considering an intermittently operated vacuum. The concern is, if they use an electric powered one, the starting & stopping will take a toll on the motor. And they’re right.

So, the Model 6193-5 Mini Chip Vac System is up for consideration. Because it’s compressed air operated, constant starting & stopping is no problem…and, it’s generating vacuum immediately, so it’s ideal for quick bursts of cleanup suction action. No electric motor to burn out, no moving parts to wear – it’s a long term, maintenance-free solution.

Quiet and compact, the Mini Chip Vac is an ideal solution for a variety of industrial housekeeping needs.

If you’re an EXAIR engineered compressed air product user, I want to thank you for your business. If you’d like to discuss a particular compressed air product application (regardless of whether you’re a current user or not!) give me a call.

Russ Bowman
Application Engineer
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Super Air Amplifiers for Cooling Injection Mold

When working with a cooling application, many customers will immediately look to the Vortex Tube and Cold Gun product lines. While this may be the best solution for some applications with smaller areas to cool, cold air from a Vortex tube based solution is not the best method for large parts or larger areas that exceed a footprint of approximately 2″ x 2″. For larger areas, we have other options for many cooling applications. EXAIR’s Super Air Amplifiers and Super Air Knives are also very effective at reducing the temperature of a part without requiring cold air.

Cooling is a relative concept based on the starting and finishing temperature. What feels “cool” to a human being does not necessarily mean the same thing as “cooling” a part or material. Due to the ability of the Super Air Knives and Super Air Amplifiers to entrain large amounts of ambient temperature air, we can move a lot of air volume across the surface of the target part and quickly lower the temperature.

A simple example I like to use is blowing on a hot cup of coffee just as its been brewed. The temperature of the air coming from your mouth is around 98.6°F, the same as your body temperature. Coffee can be as hot as 185°F when fresh. Due to the temperature differential between your breath and the hot coffee, we’re able to achieve a reasonable amount of cooling just by simply blowing across the surface. Typically, when the target temperature of the part or material needs to be around ambient temperature or higher; the best solution for cooling is going to be either a Super Air Amplifier or Super Air Knife.

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EXAIR 5015 Cold Gun

To illustrate the above concept even more, recently I was working with a customer that needed to cool a silicon injection mold. The mold had two sides and the customer was looking for a method of cooling it down between cycles. The mold cavity surface was approximately 400°F and they wanted to get it down to around 150°F. They were familiar with the EXAIR Cold Gun as they use them across their facility in various secondary or post-molding drilling operations. They had a spare and decided to hook it up and blow the cold air across the face of the mold to see what happens. The volume of air from the Cold Gun was not enough to sufficiently cool the entire mold, so he reached out to EXAIR for assistance.

Based on the dimensions of the mold and understanding the target temperature to be 150°F, we settled on a system of (2) 120224 4” Super Air Amplifier Kits. One was placed above each side of the mold. As soon as the mold opened, they activated the Super Air Amplifiers and were able to pull the surface temperature of the mold down to an acceptable level. Time is money in any manufacturing operation. Companies that produce injection molded parts will look for any way to improve their process. By implementing a procedure to cool the mold more quickly, they are able to boost their productivity gains and become more profitable.

The Super Air Amplifier Kit comes with an Auto-Drain Filter to keep the air clean and dry, a pressure regulator to allow you to dial in the precise level of airflow, and a shim set that allows you to make gross adjustments to the flow. The Super Air Amplifier is available in (5) different sizes with ¾” up to 8” diameter outlets and flow rates from 219 SCFM to 9,000 SCFM 6″ from the outlet. They are capable of achieving an amplification ratio of up to 25:1 from the compressed air supply. The laminar airflow from the unit minimizes wind shear to produce sound levels that are typically three times quieter than other air movers. If you have an application that requires a similar type of cooling, give us a call. We’ll walk you through the process of selecting the most suitable solution.

Tyler Daniel
Application Engineer

E-mail: Tylerdaniel@exair.com
Twitter: @EXAIR_TD

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