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.

saw_2-2

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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Super Ion Air Wipe Used to Fix an Encoder

A wire manufacturer contacted me about a static problem that was occurring with their encoder. The customer explained the application problem involving an encoder used to measure the length of wire running through the process.  An encoder is an electromechanical device that can count segments of revolutions as it turns.  They had a small steel wheel attached to the encoder that would ride on a nylon coated wire.  As the wheel turned, the signal from the encoder calculates the length very accurately.  The issue with the steel wheel was slippage.  The friction between the steel wheel and the nylon coated wire was not high enough due to varying tensions.  The result was the length was not counted accurately, and with large spindles of wire, they were losing money.  To fix the problem, the wire manufacturer decided to change the wheel to a fabric type to increase friction.

8462 Super Ion Air Wipe

8462 Super Ion Air Wipe

They did solve their friction problem, but now the issue became a static problem. The two non-conductive (insulated wire and fabric wheel) materials started to generate enough static electricity that a spark would ground out against the encoder body.  The sparks have a high potential to damage the encoder or cause a false count.  Either way the customer knew he had to remove the static.  Once I understood the problem, I suggested the 2” Super Ion Air Wipe, model 8462.  It comes complete with the Super Ion Air Wipe, power supply, filter, and regulator.  It is designed to provide a uniform 360 degree ionized airstream directed conically to a continuous stream of material such as insulated wire.  With the proper mounting, the Super Ion Air Wipe would remove the static from entire area, the wire and the wheel.  This removed the static issue from the process and allowed the encoder to count correctly and accurately.

Static can become a real issue within processes like this, discharging to sensitive components and operators. If you run into issues with static in your process, no matter the shape, EXAIR has the product to help.  You can discuss your application with us by contacting one of our Application Engineers.

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

Super Air Wipe for a Galvanizing Application

Wire galvanizing machine

Section of wire galvanizing machine

I saw this machine in the faraway corners of a Thai wire manufacturer’s facility.  The manufacturer galvanizes their wire to protect it from corrosion and physical damage, and after the hot dip process, the wire must be wound.  But, before the wire can be wound, it travels through this machine, which serves as a sort of quality control for the finish of the galvanization.

As the wire passes from bend to bend, it approaches a final stage in which any excess zinc is removed from the OD of the wire, which, prior to my visit looked like the photo below.

Wire galvanizing machine homemade air wipe

This short cylinder with a center hole to accept the wire  is an inefficient, homemade blow off

The performance of this homemade blow off was unrepeatable, and the end user had questions about whether the compressed air was being used efficiently.  To find out, we connected a Digital Flowmeter, and found that this homemade device was consuming twice what a comparable Super Air Wipe requires at the same pressure.

We then connected a Super Air Wipe to find that the blow off was not only stronger, but more uniform from the EXAIR unit.  And, the clamshell design of the Super Air Wipe can allow the installation to occur at any point along the process, without requiring that the wire is “threaded” through the Air Wipe.

If you have a similar application, or one that you think may be candidate for an EXAIR solution, contact an EXAIR Application Engineer.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Air Nozzles Can Blow Off And Clean Wire

Wire After Water Quenching

In my blog last week I mentioned an application to dry extruded rubber after quenching in a dip tank.  This week I was again contacted for a similar application, only this time the need was to dry a copper wire after quenching.  The current setup (above) used rollers to remove water and debris, but failed to solve the problem.

In most applications like this, a Super Air Wipe will be the best solution.  An Air Wipe will provide 360° blow off of the part, keep compressed air use low, and keep noise low as well.  However, when the diameter of the product is very small, we can also meet the needs of the application by using properly positioned Super Air Nozzles.

In this application, the diameter of the wire could be as small as 2mm, so I was inclined to offer an air nozzle based solution.  For example, EXAIR 1109SS Pico Super Air Nozzles mounted around the OD of the wire using Stay Set Hoses, and positioned with 45° angles of attack could provide blow off and cleaning of the small diameter wire.  It would also provide a degree of adjustment for the other small diameter wires.  Given the variable diameters of the wires in this application, I recommended testing of the nozzle based solution. Speed is another consideration in a wire blow off application, in this application the wire will exceed 1000 feet per minute (fpm). We generally recommend a Super Air Wipe Solution when speeds are below 1000 fpm.

If you have questions about which EXAIR solution will best solve the problem in your application, we are here to help.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

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