Adjustable E-Vac Saves Coolant

Many EXAIR Corporation blogs could use this formula as the title:

[EXAIR Intelligent Compressed Air Productsaves  [valuable commodity in customer’s facility]

Popular examples might be:

But how exactly does an Adjustable E-Vac Vacuum Generator save coolant?  Isn’t that what the Chip Trapper Systems do?  (It is, and that’s been covered extensively here, here, and-my personal favorite-here.)

Our E-Vac Vacuum Generators are probably most commonly used in pick-and-place applications, in conjunction with our Vacuum Cups.

From a lightweight manual operation to an automated system with large or heavy objects, the EXAIR E-Vac Vacuum Generators can solve the application.

The Adjustable E-Vacs, however, have a unique feature – a relatively large throat diameter – that makes them well suited for suctioning up liquids.  And I recently had the pleasure of helping a caller with just such an application.  They make machinery for the automotive industry, and in one particular operation, coolant gets left behind in ‘pockets’ of a particularly unwieldy piece.  They can drain most of it at the machine, but what gets left behind in these pockets makes a real mess as it goes to the next fabrication point, and, although it’s a small amount in each pocket, it adds up to a finite amount of wasted coolant.  It’s not practical to use an electric shop vacuum, but an operator could easily use a handheld device to suck up these little puddles.

Enter the Adjustable E-Vac…with the wide throat diameter I mentioned above and compact design, they were able to install a short suction hose (via a threaded push-in connector) to the vacuum port, and a little longer discharge hose to the exhaust port, and they have a quick and easy, portable, maneuverable coolant transfer system.  Here’s a short video I made in the Demo Room, once upon a time, showing how it works:

Saving air.  Saving coolant.  Saving money and time, one compressed air application at a time.  If you have one you’d like to discuss, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Video Blog Cooling Comparison: EXAIR’s 2″ Super Air Amplifier vs. Fan

Super Air Amplifier

EXAIR‘s line of Adjustable and Super Air Amplifiers are the ideal solution for cooling hot parts. Using a small amount of compressed air, they’re designed to entrain massive amounts of free ambient air from the environment. This free air mixes with the primary air stream, achieving entrainment ratios of up to 25:1!

To demonstrate the dramatic difference between the Super Air Amplifier and a standard fan, I created a side-by-side video of the two. Using the 2″ Model 120022 Super Air Amplifier at just 40 PSIG (9 SCFM air consumption) check out just how effective we were at cooling down a stainless steel block:

When fast cooling of a hot part is necessary, look no further than EXAIR’s Adjustable and Super Air Amplifiers. They’re all in stock and can ship same day to the US & Canada with an order placed by 3:00 ET!

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

 

Adjustable Air Amplifier Transfers Plastic Bag Scrap

Many times EXAIR products are used to help sort materials based on their weight or their density by providing a consistent force against a series of targets that should be of the same density or weight, but when they are not, the airflow can be “tuned” to remove the non-conforming parts.

aal-vacuum
Model 6042 Aluminum Adjustable Air Amplifier rejects empty pouches.

In this case, our customer (a packaging automation specialist) was working with a form fill and seal machine that was dedicated to making pouches 2” x 8” and filling them with a food product. In some cases, the pouches would not become filled with product and needed to be removed from the line. So, our customer devised a way to mount model 6042 2” Adjustable Air Amplifier along-side the travel of the pouches and set the input pressure and air gap setting to get optimum vacuum capture velocity to suck away empty ones and leave the full ones in-tact. Above you can see a photo that the customer took while mocking up the application at their facility. You can see the hose connected to the output to direct the empty pouches to a wire basket below.

A couple of things in this application made use of the Adjustable Air Amplifier the best choice. The first was the funnel-shaped suction area on the back side of the Adjustable Air Amplifier. This optimizes the Air Amplifier’s ability to draw in ambient air to propel it to the outlet. In doing this the un-filled, light-weight, plastic pouch becomes caught in the high velocity stream and thus gets carried away as desired. The second thing is that since compressed air is the source of power, the customer has infinite adjustability over the amount of suction force that they can apply to the pouch in the application. They can adjust the air gap opening on the Adjustable Air Amplifier to have a coarse adjustment of air consumption as well as vacuum level. Then, they have a finer adjustment that a pressure regulator can provide to really dial in the suction force as they need it to be for removal of the empties.

The idea here is that while Air Amplifiers are generally used for their output flow to cool targets and provide a significant Blowoff force, they can also be used to draw in not only smoke and fumes but also other lightweight items like the empty pouches above.

If you have a need to set up any kind of sorting process, maybe just to separate two different recycling streams or perhaps it is a need to perform a quality control function as shown above, think about EXAIR and our many solutions in this area.

Neal Raker, International Sales Manager
nealraker@exair.com
@EXAIR_NR

What is the Venturi Effect?

In 1797 a Italian physicist named Giovanni Battista Venturi wrote a dissertation on the “Venturi Effect”.  However, an actual device was never created or applied until 1888 where Clemens Herschel was awarded the patent for the first Venturi tube.

The Venturi effect is a decrease in fluid pressure when fluid flows through a constricted area of a pipe.  In other words, as the diameter becomes smaller, the fluid velocity becomes faster.  This increase in velocity will create a lower pressure just past the constricted area.  When designed correctly, you can create a strong vacuum or a large negative pressure.

The EXAIR E-Vac® Vacuum Generators use this phenomenon by using compressed air as the fluid.  This type of Venturi tube restricts the internal area to generate a fast velocity through the body creating a vacuum pressure for suction.

EXAIR offers three types of Venturi tubes; low vacuum, high vacuum and adjustable.  Low vacuum units are typically used with porous material because the trade off for low vacuum is higher vacuum flow. The high vacuum generators can create a vacuum level as high as 27” Hg (71 KPa).  The Adjustable E-Vacs can alter the internal air velocities by turning the body and getting different vacuum pressures.  Without any moving parts or electric motors to break, the EXAIR E-Vacs are a simple design that is very durable, effective and long-lasting.  A great product for applications like pick and place, clamping, lifting and vacuum forming.

In-Line E-Vac How It Works
EXAIR E-Vacs provide instantaneous vacuum response, and are engineered for high efficiency to minimize air consumption.

The Venturi effect was discovered in 1797, brought into existence in 1888, and is still used in vacuum applications to this very day.  If you have an application where a Venturi tube could help you, please contact an Application Engineer.  We will be happy to assist you.

Jordan Shouse
Application Engineer
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How to Choose A Vacuum Generator for Your Application

EXAIR’s compressed air powered E-Vac single stage vacuum generators are a low cost way create vacuum for many operations including- pick and place, clamping, chucking, alignment, lifting, and many others.

The E-Vac provide instantaneous response and are commonly used for pick and place operations.

EXAIR offers the In-Line and Adjustable style of E-Vacs. Both are compact and easy to mount at point of use. With 18 total models available, there is sure to be one that meets any application.

Industrial Robot
An E-Vac in Robotic Lift Operation

How to Build An E-Vac System:

Step 1 – Select E-Vac type:

A – Determine if the part to be lifted is porous (Example, cardboard) or non-porous (Example, plastic sheet)

  • Porous materials require a low vacuum generator which produces a lower vacuum in exchange for higher vacuum flow which is capable of maintaining a good vacuum level through material that aloows air to flow through itself.
  • Non-Porous materials are best suited to use the high vacuum generator which is capable of producing more powerful vacuum for the application.

B – Select a style of E-Vac – In-Line Low Vacuum, In-Line High Vacuum, or Adjustable

  • Porous – low vacuum generator, max vacuum = 21″ Hg (71 kPa)
  • Non-Porous – high vacuum generator, max vacuum = 27″ Hg (91 kPa)
  • Adjustable – max vacuum = 25″ Hg (85 kPa)

Step 2 – Find the weight of the part to be lifted:

Step 3 – Multiply the weight by a vacuum cup safety factor (2 for a horizontal vacuum cup position, and 4 for a sideways vacuum cup position)

Step 4 – Determine the number of cups needed, considering the following:

A – How many cups are needed to evenly distribute the weight for stable lifting and placement.

B – What is the weight that each vacuum cup can lift based on maximum vacuum available?

C – Select the appropriate vacuum cup from the different styles available.

Step 5 – Choose the E-Vac model, considering the entire vacuum system from the E-vac to the part:

A – Number of vacuum cups per E-Vac.

B – Length and size of the vacuum tubing.

C – Vacuum cup size and type.

  • The volume of air to evacuate from your vacuum system and the vacuum flow of the E-Vac selected will determine the time it takes to build the lifting vacuum level.
  • A lower volume of air in the system and/or higher capacity (SCFM/SLPM) E-Vac will result in faster pick-up times.
  • It is difficult to calculate an exact pick-up time.

Example – Sheet of material 3′ x 3′ (0.91m x 0.91 m) that weighs 25 lbs. (11.3 kg). Each sheet is in stack and will be placed on a conveyor.E-Vac Example

As you can see, there is a lot to consider when building an E-Vac system. Feel free to contact us and we can help go through the steps.

If you have questions about E-Vacs or any of the 15 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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Air Entrainment & EXAIR’s Intelligent Compressed Air Products

Air entrainment is a term that we bring up quite often here at EXAIR. It’s this concept that allows many of our products to dramatically reduce compressed air consumption. The energy costs associated with producing compressed air make it an expensive utility for manufacturers. Utilizing engineered compressed air products that will entrain ambient air from the environment allow you to reduce the compressed air consumption without sacrificing force or flow.

Entrainment
EXAIR Intelligent Compressed Air Products such as (left to right) the Air Wipe, Super Air Knife, Super Air Nozzle, and Air Amplifier are engineered to entrain enormous amounts of air from the surrounding environment.

Products such as the Super Air Knife, Super Air Nozzle, Air Amplifier, and Super Air Wipe all take advantage of “free” air that is entrained into the primary supplied airstream. This air entrainment occurs due to what is known as the Coanda effect. Named after renowned Romanian physicist, Henri Coanda, the Coanda effect is used in the design of airplane wings to produce lift. As air comes across the convex surface on the top, it slows down creating a higher pressure on the underside of the wing. This creates lift and is what allows an airplane to fly.

nozzle_anim_twit800x320
EXAIR Super Air Nozzle entrainment

This is also the same principle which is allowing us to entrain ambient air. As the compressed air is ejected through a small orifice, a low-pressure area is created that draws in additional air. Our products are engineered to maximize this entrained air, creating greater force and flow without additional compressed air. Super Air Amplifiers and Super Air Nozzles are capable of up to a 25:1 air entrainment ratio, with just 1 part being the supplied air and up to 25 times entrained air for free!! The greatest air entrainment is achieved with the Super Air Knife at an incredible ratio of 40:1!

This air entrainment principle allows you to utilize any of these products efficiently for a wide variety of cooling, drying, cleaning, or general blowoff applications. In addition to reducing your compressed air consumption, replacing inefficient devices with engineered products will also dramatically lower your sound level in the plant. Sound level in some applications can even be reduced down to a point that would eliminate the need for hearing protection with the OSHA maximum allowable exposure limits set at 90 dBA for an 8-hour shift.

If you have inefficient blowoff devices in your facility, give us a call. An Application Engineer will be happy to help you select a product that will “quietly” reduce your compressed air consumption!

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

Types of Air Amplifiers: Amplify Volume or Amplify Pressure

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

As Application Engineers, we help many customers with finding solutions with effective, safe, and efficient EXAIR products.  But, in some instances, we get a request for an air amplifier to increase line pressures.  EXAIR does not manufacture this type of Air Amplifier.  In doing some research on the internet, I was able to find two different types of air amplifiers.  In this blog, I will describe the difference between the pressure-type and volume-type.

The EXAIR Super Air Amplifiers are defined as a volume-type of an amplifier.  They use compressed air to generate a large volume of air flow.  The amplification ratio is the comparison between the inlet air flow and the outlet air flow.  With the EXAIR Super Air Amplifiers, we can reach an amplification ratio of 25 to 1.  They use a Coanda profile with a patented shim to create a low pressure to draw in a large volume of the surrounding air.  EXAIR manufactures a variety of different sizes, materials, and types.  But they all do the same thing, amplify the volume of air.  To give an example, model 120024 Super Air Amplifier has a 25:1 amplification ratio.  It uses 29.2 SCFM (826 SLPM) of compressed air at 80 PSIG (5.5 bar).  So, the outlet air flow is amplified from 29.2 SCFM to 730 SCFM (20,659 SLPM) of air.  This large volume of air works great for cooling, exhausting, and transferring.  But, with any type of amplification, you have to lose something.  With the volume type Air Amplifiers, the outlet pressure is reduced dramatically.

The pressure-type air amplifiers are different from the Super Air Amplifiers as this device will amplify the outlet air pressure, not the volume.  It is an air pump that has a direct dual piston that uses two different diameters.  The larger diameter uses the drive inlet pressure while the smaller diameter is used for the boost pressure.  The amplification ratio is determined by the difference in volume from the drive piston to the boost piston.  They also come in a variety of ranges and sizes.  As an example, an amplification ratio of 15:1 will increase an inlet pressure from 100 PSI (7 bar) to an outlet pressure of 1,500 PSI (103 bar).  Since the pressure-type air amplifier is an air pump, the system has to cycle.  To do this, they use pilot valves to either add the inlet compressed air to the drive piston or to relieve the air pressure from the drive piston.  This cycling portion of the operation does reduce the efficiency of the air amplifier.  The pressure-type air amplifiers are used to generate high pressure for a specific application or area and eliminate the purchase of a high-pressure air compressor.  The applications include air clamps and presses, pressure testing, air brakes, and also blow molding.  Like stated above about losing something with amplifications, the volume of air is reduced dramatically.  Generally, a reservoir tank and over-sizing will be needed for a good system.

The Application Engineers at EXAIR enjoy talking to customers about compressed air applications.  If you need more information about Air Amplifiers, you can contact us directly.  We can explain the volume-type that we manufacture or refer you to a company that makes the pressure-type.  Either way, we will be happy to hear from you.

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