EXAIR’s Super Air Wipe – 360° Airflow Pattern for Blowing, Cleaning, and Drying!

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Model 2402 2″ Super Air Wipe removing water from PVC tubing

A close relative to the Super Air Knife, the Super Air Wipe provides a uniform 360° laminar airflow for blowing off, drying, cleaning, and cooling a wide variety of pipe, cable, extruded shapes, hose, and wire. Its split design allows it to be easily clamped around the surface of the material without having to “feed” the material through.

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Model 2404SS 4″ SS Super Air Wipe

The Super Air Wipe is available in aluminum construction in sizes ranging from 3/8” – 11” diameter. All Super Air Wipes comes with stainless steel hardware and stainless steel shims. Sizes up to 4” include plumbing to supply both halves of the Super Air Wipe. Sizes over 4” should be piped directly to each ¼ NPT compressed air inlet on each half. In addition to aluminum construction, the Super Air Wipe is also available in 303 stainless steel for corrosive or high temperature applications. The Stainless Steel Super Air Wipe can withstand temperatures up to 800°F and is available in sizes from ½”-4” from stock.

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Sizes available from stock

Much like the Super Air Knife, the Super Air Wipe has ¼-20 tapped holes along the downstream side that can be used for mounting. Smaller Super Air Wipes can be supported by rigid compressed air pipe that is used to supply the unit. The Super Air Wipe is also infinitely adjustable through the use of shim sets or a pressure regulator. Kits will include the Super Air Wipe, shim set to make gross adjustments to the airflow, an auto-drain filter to keep the air clean and dry, and a pressure regulator. By adjusting the input supply pressure to the Super Air Wipe, you regulate both the force and flow that is projected onto the target material. Increasing the input supply pressure will increase both the force and flow from the Super Air Wipe. This video blog demonstrates how effective the Air Wipe is when drying 1-1/2” PVC pipe:

If you’re processing any type of hose, wire, or extruded shapes that could benefit from installing a Super Air Wipe, give us a call. With all sizes shipping from stock on an order received by 3:00 pm EDT we can have one to you as early as tomorrow!

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

Super Air Wipe Helps Shield a Lens

Super Air Wipe Kit

A tier 2 automotive company makes small metal boxes with a process which includes laser welding and a vision inspection system. The machine was programmed to weld different components onto the metal enclosure. During the welding operation, an optical sensor would check the quality of the welds. The vision system used a lens to protect the sensor from welding slag and debris. After a few operations, they started seeing false positives in the welding areas, and the metal enclosure would be flagged for rejection. In investigating the issue, they found that the lens was getting dirty from the welding operation. Because of the sensitivity of the sensor, it would detect the debris and marks on the lens and signal for poor weld. The lens was doing its part in protecting the sensor from damage; but, they needed a way to shield the lens from dirt and slag during the welding operation and visual inspection.

With this process, the machine would weld metal fasteners onto an enclosure by laser. The optical sensor would move along the welded areas to check the quality. In a lead/lag operation, the vision system would check the welds after a few seconds of cooling. So, both operations were occurring at the same time but at different intervals. When they started to see the rejection rate increase, they would have to stop the operation, clean the lens, and verify the integrity of the welds. In some cases, they would have to replace the 1 ¼” diameter lens especially if a piece of welding slag marred the surface. With incorrect rejections and lens cleaning, downtime was hurting their production rates and cost.

This customer wanted to use compressed air because it is a powerful and invisible way to create a shield. Since EXAIR is a leader in efficient and effective ways to use compressed air, they contacted us for help. Initially, I suggested a Super Air Knife to deflect any slag and debris from the lens surface. I showed a prior solution to a very similar issue; “Air Shielding a Laser Lens” (Reference below). But, because of the proximity to the part and the limitation in space, the Super Air Knife  configuration in the solution below would make it impossible to use. They were looking for a product that could be mounted either flush or behind the surface of the lens and still protect it.

Air Shielding a Laser Lens

To accommodate for this request, we had to direct the compressed air stream at an angle. EXAIR manufacturers a product that can do just that, the Super Air Wipe. The design of the Super Air Wipe blows compressed air at a 30-degree angle toward the center in a 360-degree air pattern, just like a cone. It can be placed around the lens and still be able to create a “wall” of air to block any slag or debris from hitting the lens.

I recommended the model 2452SS, 2” Super Air Wipe Kit. This Super Air Wipe has the body, braided hose, hardware, and shims that is made from stainless steel. It can handle the high heat loads from the welding process as well as to allow for easy cleanup after a day of operating. The kit includes a filter, to keep the compressed air clean; a regulator, to finely tune the force requirement; and a shim set. The shim set includes two additional sets of shims that can be added to increase the force of protection if needed. With the kit, the customer can “dial” in the correct amount of force needed to keep the lens clean without using excessive amount of compressed air.

As an added benefit of saving compressed air, the Super Air Wipe uses the Coanda effect to maximize the entrainment of ambient air into the compressed air stream. This makes the unit very efficient and very powerful. The Super Air Wipe was mounted just behind the lens like the customer required (Reference mock picture below), and the sensor could examine the welds without any interference with the metal enclosure.

Laser Lens mock drawing

Visual inspections systems are highly accurate pieces of equipment, and a dirty lens will affect the performance. EXAIR has many ways to keep the lens clean with a non-contact invisible barrier to protect sensors, cameras, and lasers. If you have a similar application, you can contact an Application Engineer to determine the best way to keep the lens clean and your equipment functional. After mounting the Super Air Wipe, the customer above eliminated any false rejections, and dramatically decreased any downtime for cleaning or replacing the lens in his welding machine.

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

Crescent Hammers, Phillips Head Punches, and Other Cautionary Tales

I don’t want to sound “preachy,” but I’m a stickler for using the right tool for the job. Case in point: just the other day, I noticed (OK; my wife told me about) a loose drawer handle. I went to my toolbox in the garage to get a flat-head screwdriver, even though the drawer in question had a selection of butter knives, any one of which could have been used to tighten that screw.

I can trace this, without doubt or hesitation, to my service in the US Navy, under the direction of Senior Chief Cooper.  Proper tool selection & use was VERY important to him.  He stressed the issues of safety, quality, and performance, but if that didn’t work, he’d make his point with an offer to demonstrate the use of a specific tool (a ball peen hammer) on a sensitive part of your anatomy (it’s exactly the part you’re thinking of.)  At that point, it would have been unwise (and unsafe) to question whether that was a proper use of the tool or not.

Only one of these is a hammer………………..….only one of these is a punch………………..…..only one of these is a chisel.
Choose wisely.

Likewise, there are safety, quality, and performance issues associated with compressed air blow offs.  At EXAIR, we’re ALL sticklers about this, and we get calls all the time to discuss ways to get more out of compressed air systems by using the right products.  Here’s a “textbook” example:

A hose manufacturer contacted me to find out more about our Air Wipes, and how they might be a better fit for their various cleaning & drying applications (spoiler alert: they are.)  The blow offs they were using were made of modular hose, designed (and very successfully used) for coolant spraying in machine tools.

Only one of these is a compressed air blow off. Again…choose wisely.

The selection process was two-fold: they purchased one Model 2401 1″ Super Air Wipe to verify performance, and they sent in some of their modular hose assemblies for Efficiency Lab testing.  The first part was just as important as the second because, no matter how much air they were going to save (another spoiler alert: it was significant,) it wouldn’t matter if it didn’t get the job done.  At the station shown above, the Super Air Wipe resulted in superior performance, and a compressed air cost savings of over $400.00 annually.  For that one station.  Based on that, they outfitted TWENTY FIVE stations with engineered product sized for their different hoses, using our Model 2400 (1/2″), 2401 (1″), 2402 (2″) and 2403 (3″) Super Air Wipes.

If you’d like to find out how using the right product for the job can help your operation, give me a call.

Russ Bowman
Application Engineer
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Super Air Wipe Controls Coating Thickness On Tubing

A large manufacturing company called looking for a better solution to control the thickness of a curing agent being applied to the outside of tubing used in the automotive industry. The tubing is formed in an extruder and travels through a liquid cooling chamber and then air dried. After the tubing is dried, it is sent to a spray chamber where the curing agent is applied to the exterior. On the exit side of the spray chamber, the customer had installed several flexible air lines placed around the perimeter of the tubing to blow air across the surface to help control the coating thickness. This worked somewhat but they were seeing an increase in the amount of rejected material as the air pattern was sporadic and uneven, which caused streaking and dry spots in certain areas of the tubing. They reviewed our web site and familiarized themselves with our Air Wipes but were unsure of the best design and size to fit their need so they reached out for assistance.

After further discussing the process, their tube O.D. sizes range from 3/8″ – 1/2″, making our 1″ Air Wipe the ideal solution. As far as the design, the Standard or Super Air Wipe, I recommended they use our Model # 2451 Super Air Wipe kit due to the aluminum construction and stainless steel wired braided hoses being able to withstand the potential temperature in the area of 200°F. The kit includes a filter separator to remove any water or contaminants in the supply and a pressure regulator which would allow them to control the flow and force of the exiting air, to help “dial” it in to fit the demand of the application.

Super Air Wipe is available in sizes from 1/2″ up to 11″ in Aluminum construction and up to 4″ in Stainless Steel construction.

 

EXAIR Air Wipes features a split design, which can easily be clamped around the material, to provide a 360° uniform airflow, perfect for treating the surface of round shapes, like extruded tubing. If you have an application where you are needing to dry, cool or clean the outside of a pipe, hose or cable, contact an application engineer for help making the best product selection.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Super Sized Is Not A Problem At EXAIR

For many years we as Americans wanted to biggie size, super size, or mega size anything and everything we could.   For myself that mainly meant the fries and drink I used to get at any local fast food joint.   Now that I have hit my mid-30s and all of that has started to catch up to me, I don’t always want the large fry or any fries at all, instead I might try a new salad and trying to eat healthy.  Here at EXAIR, we don’t always associate bigger with better but we do always fill the need when we don’t have something off the shelf.

However, there are still occasions where going super size is necessary and this week, we did just that.   We had a customer ask if we can go bigger on our Super Air Wipes.   We simply asked how big they needed to go and what the reasoning is for it.  Turns out, the reasoning for the larger Super Air Wipe was a newly designed automated cell in a pipe manufacturing facility.   The stock 11″ was too small to fit the 11″ max. diameter piece through to blow off debris so they requested a 12″ Super Air Wipe.   To top off the customization, they were also in need of BP threaded air inlets.

Catalog 30 Stock Air Wipe Sizes

Within a matter of weeks our customer has gone from a product they didn’t know was possible, to shipping out to their site.  This is a one off, custom machined, Super Air Wipe that has a 12″ Throat Diameter.   The only parts on this that are from our standard stock are the bolts, stickers, and the connecting / hinge plates(The clam shell design requires these.).

If you have an application where you don’t think we have exactly what you need or maybe you need to go bigger, or smaller, than what we show in the catalog don’t move on and try to find something else.   Give an Application Engineer a call and we will see how we can tailor our products to your exact needs.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

Drying and Cleaning Tubes Using The Standard Air Wipe

A tubing manufacturer called looking for a better way to dry their 3″ (O.D.) tubes after a rinse application. In their current setup, the tubes are being cut by a band saw, which uses flood coolant to keep the blade cool and evacuate chips. After the tubes are cut, they are then bundled together and dipped into a rinse tank to remove the cutting fluid and any machining debris on the surfaces. The tubes are then fed, one by one, through a series of blower driven air knives placed around the outside  of the tubing to dry and clean them before a painting and bar code process. The air knives were working somewhat, but they were seeing some residual streaking on the surface of the tubes that needed to be manually cleaned by hand, slowing down the process.

Example of a typical band saw used for cutting metals and other rigid material.

I recommended the customer use our 4″ Standard Air Wipe in their application. EXAIR Air Wipes provide a 360° uniform, high velocity airflow that adheres to the outside surface, as it passes through the throat of the device. Here is a short video we made showing the cleaning power of our Standard Air Wipes.

The Standard Air Wipe is available in stock sizes from 1/2″ up to 11″. The aluminum construction and PVC hose (included on sizes up to 4″) is suitable for most “general” industrial environments with ambient temperatures reaching as high as 150°F. We also offer Stainless Steel Super Air Wipes, which have the same performance as the Standard, for processes requiring superior corrosion resistance and/or where higher temperatures are possible, up to 800°F.

Super (left) and Standard (right) Air Wipes – ideal for drying, cleaning or cooling round shapes like tubing, hose, pipes, etc.

For help selecting the best product to fit your particular need, please contact an application engineer for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

FMB FMB Titan Bandsaw Gravity Feed image courtesy of Kitmondo Marketplace via Creative Commons license.

Super Air Wipe Cools, Cleans and Dries Extruded Shapes

We have many customers that use the manufacturing process of extrusion to make their various type of products.  EXAIR has an Intelligent Compressed Air Product that works very well with these processes to provide a drying, blowoff and cooling function.

Many types of products are produced via the process of extrusion, which is to shape (as metal or plastic) by forcing through a die.  There are many advantages to the extrusion process, including it being a continuous operation, it runs at high speeds, is good for high volume and low production costs, as well as many other factors.

The extrusion process typically requires heating of the metal billet or melting of the plastic to a high enough temperature to allow it to flow and be shaped as it it forced through the die. After the product has passed through the die and has been shaped it must be cooled and this is usually achieved by passing the it through a water bath.  Once the material has been cooled, it needs to be dried to remove the moisture, before the extrusion enters the next stage of processing, like getting cut to length or printed upon.

The EXAIR Super Air Wipe is ideal for blowoff, drying, cleaning and cooling of continuous materials such as extrusions, pipe, cable and more.

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The Super Air Wipe has a split design which offers easy clamping around the surface of the material, eliminating the need for threading. All Super Air Wipe models include stainless steel screws and shims.  Stainless Steel wire braided hose which is plumbed to each half, is included on sizes up to 4″ to simplify installation and plumbing. Aluminum models are rated to 400°F and the stainless steel models for temperatures up to 800°F.  Models are available in size from 1/2″ to 11″ Throat Diameters.

The Super Air Wipe provides a uniform, 360° air stream that is ideal for drying and cooling of extruded materials.

To discuss your application and how an EXAIR Super Air Wipe can benefit you extrusion process, 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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