Thursday, 24 September 2020

How to Pick the Right Atomizing Spray Nozzle

 Atomizing spray nozzles atomize fluids with compressed air to create a fine spray in a variety of patterns for a variety of uses. They are commonly used to mark products, paint or coat, cool, reduce dust, lubricate and clean parts.

With the numerous types of Atomizing Nozzles, it can be challenging to sift through all the information. But with a few basic questions you can narrow down the right nozzle type for you and your application:

Are you using a pressurized liquid feed? In some cases, a pressurized liquid source is not available for the nozzle, so you would have to rely on a gravity or siphon fed nozzle. While you lose the complexity of having a liquid pump pressurizing your liquid, you do have a few draw backs. Your siphon height is typically with in 36” so your liquid source has to be fairly close to your nozzle. Siphon fed nozzles are hard to turn off and on, they are best used for applications where you are continuously spraying a low viscosity liquid with a low gph. 


What is the viscosity of the fluid? Another deciding factor is the viscosity of the liquid you are spraying. Different nozzles are designed for different viscosity. For example, two of the main nozzle types are internal mix nozzles and external mix nozzles. They function just like they sound, internal mix nozzles mix the compressed air and liquid source inside the nozzle. And because of this they typically can not spray liquids over 300 cP. And because external mix nozzles mix the liquid and air outside the nozzle, they can handle liquids well above 300 cP.

What is the liquid flow rate in gallons per hour(gph)? Another factor in choosing the right nozzle is if your application has a set gph you are looking to achieve. Some nozzles are designed to flow more liquid then others. For example, the external mix nozzles inherently flow more liquid then the internal mix. As there is less restriction on the liquid flow. If you are looking for even higher gph you can source a liquid only atomizing nozzle, its going to give you a large bump in gph. But your droplet size will suffer with the liquid only nozzles.

What droplet size are you looking for? Fine droplet sizes are one of the primary reasons atomizing nozzles are used. Benefits of small droplet sizes include even coating and liquid conservation. Internal mix nozzles will do the best at providing the smallest droplet size possible. While external mix and liquid only will give you larger droplet sizes but they will give you a larger gph some applications need.  

Should I use a No-Drip option?  The No-Drip option positively shuts off liquid flow when the    compressed air supply is shut off.  One benefit of this is appreciated in coating applications, where an errant droplet of liquid would mar an otherwise smooth, even coating.  Operationally, though, it also means you can precisely turn the liquid flow on & off, in short, quick bursts, up to 180 times a second.
If you are in the need for a Liquid Nozzle to assist in your facility, please reach out!

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Vivek Engineers
#22, 1st Floor, 1st Cross, Adj. to IIMB Compound, Bilekahalli Indl. Area, 
Bannerghatta Road, Bangalore - 560 076 
Ph : 080 -  2648 1309, 4170 1145.
Mob : 097404 39220






    




Tuesday, 22 September 2020

Offshore Pipe Welding Cooled with Series of EXAIR Super Air Nozzles

One of the services we provide to our customers, is assistance in selection of the most suitable product solution for their application.  For most applications we have solutions readily available from stock, though that wasn’t the case in the solution shown above.

This configuration of model 1122 Flat Super Air Nozzles is used to cool pipe welds in an application located off the coast of France.  Pipes with an OD of 450mm (~18”) are welded together, and in order for the welds to be of the highest quality, they must be cooled.  To cool the welds, this customer needed to blow ambient temperature air over the pipes.

Initially, we explored a Super Air Wipe solution.  A Super Air Wipe can provide a full 360° blow off for this pipe, but there was an aspect of the application which led to a better solution through nozzles; an irregularity in position of the pipe.


The diameter of the pipes in this application is relatively constant, but there is some fluctuation in position as the pipe is moved.  If using a Super Air Wipe, this could mean contact with a precision machined surface, resulting in a change to the performance of the unit.  But, what if we could find a way to allow the blow off solution to have some “flex”.



“Flex” in this solution is provided through the use of EXAIR model 9053 swivel fittings, shown above with red circles, each used to mount an 1122 Flat Super Air Nozzle (16 of each).  These allow for proper placement of the nozzles, and also for movement if anything should ever contact the blow off solution.

An additional benefit of the EXAIR 1122 nozzles used in this application, is the ability to exchange shims inside the nozzle to increase or decrease the amount of force delivered from the nozzle.

Understanding the critical requirements of the customer led to this semi-custom solution using EXAIR Super Air Nozzles.  If you‘d like to explore an EXAIR blow off solution for your application, contact an Vivek Engineers Application Engineer.

<<CLICK HERE>> to visit our website

Vivek Engineers
#22, 1st Floor, 1st Cross, Adj. to IIMB Compound, Bilekahalli Indl. Area, 
Bannerghatta Road, Bangalore - 560 076 
Ph : 080 -  2648 1309, 4170 1145.
Mob : 097404 39220






    





Friday, 18 September 2020

EXAIR’s New EasySwitch Wet/Dry Vac Operation

 EXAIR introduced our first Wet/Dry Vacuum in August. We have simplified the process of converting a vacuum from wet to dry (and dry to wet) materials. This can now be easily switched within 15 seconds due to its patent pending engineering and design. The video below is a quick rundown of just how easy it is to contain any industrial mess with the new compressed air powered vacuum from EXAIR.


If you would like to discuss the EasySwitch Vacuum options and kits available from stock, please contact us.


<<CLICK HERE>> to visit our website



Vivek Engineers
#22, 1st Floor, 1st Cross, Adj. to IIMB Compound, Bilekahalli Indl. Area, 
Bannerghatta Road, Bangalore - 560 076 
Ph : 080 -  2648 1309, 4170 1145.
Mob : 097404 39220






    

Monday, 14 September 2020

EXAIR VariBlast Safety Air Gun

 Air guns can be found in nearly any industrial facility that has a compressed air system within it.  From the maintenance department to the production floor, operators potentially use these for anything from, cleaning up work areas,  to blowing product out of a troubled spot in a process. Handheld blowoffs are often overlooked as a means to increase efficiency yet they are often observed as a means to increase safety.


When evaluating efficiency the length of use for a handheld blowoff is often variable from operator to operator as well as changes even from each use.  Often, operators have several different uses throughout their day that require different levels of force needed to complete the job.  Most safety air guns don’t offer a variable force.  This means operators are full-force for all applications. This means full air consumption whenever that gun is used. EXAIR’s VariBlast Compact Safety Air Gun can help to give operators the adjustability they need.


The VariBlast Compact Safet Air Gun is available from stock with over a dozen options of different Super Air Nozzles as the end defector of the Safety Air Gun.  These are any nozzle up to a 1/8″ NPT thread size.  To couple with these engineered nozzles, we offer stock length extensions up to 72″ (1829 mm)  in length. This makes many applications that are hard to reach easily managed by the operators.


To couple with the extensions and make sure the VariBlast Compact Safety Air Guns all meet or exceed OSHA standards for operator safety, we offer a Chip Shield accessory as well.


If you would like to discuss how to lower the demand placed on your air compressor from blowoffs and want to better experience what true variability as well as what an engineered blowoff is capable of, contact us.

<<CLICK HERE>> to visit our website


Vivek Engineers
#22, 1st Floor, 1st Cross, Adj. to IIMB Compound, Bilekahalli Indl. Area, 
Bannerghatta Road, Bangalore - 560 076 
Ph : 080 -  2648 1309, 4170 1145.
Mob : 097404 39220






    



Wednesday, 9 September 2020

Super Air Amplifiers vs. Electric Fans

 EXAIR’s product offerings contain many products that can be used for cooling. The focus of this blog will be .Super Air Amplifiers These often times get placed in a head to head competition with an electric fan. The best part, they easily come out on top.

When looking at the benefits other than performance and rate of cooling due to air entrainment, many customers prefer the Super Air Amplifier due to the fact there are no moving parts. This comes into play when cooling within in a hard to reach area or within a harsh process is needed.  Placing an electric motor with a blade held on by fasteners may not be desirable from a maintenance standpoint. The Super Air Amplifiers do not require electricity, meaning there is not a motor or bearings that would need to be replaced or inspected.

Another benefit is the small footprint of the Super Air Amplifier. This can also be seen within the video above where the Air Amplifier is shown is able to produce 341 SCFM (9,650 SLPM) in amplified airflow.  This gives the ability to place a small unit inside of a chamber that needs large volumes of air flowed through it.  For instance, a rotomolded part that has a large chamber and it needs surfaces to be cooled in order for the part to hold its shape from the mold rather than warp.  This can also be coupled with the fact that a Super Air Amplifier can be ducted on either the suction or discharge side in order to retrieve cool air or move the warm air out of the area.

Speaking of warm, the Super Air Amplifiers are also manufactured to withstand up to 275°F (135°C) from stock.  Stainless Steel and High-temperature models go well beyond that temp, as seen above. Custom-designed (flanges and different materials are common) versions are also available in short lead-times.

If you would like to discuss the benefits to a Super Air Amplifier further, feel free to contact us.


Vivek Engineers
#22, 1st Floor, 1st Cross, Adj. to IIMB Compound, Bilekahalli Indl. Area, 
Bannerghatta Road, Bangalore - 560 076 
Ph : 080 -  2648 1309, 4170 1145.
Mob : 097404 39220






    


Monday, 7 September 2020

EXAIR Safety Air Guns: Quiet, Safe, And Efficient Blowoff (Literally) In The Palm Of Your Hand



One of the more popular uses in industry for compressed air is blowing off parts or products, and one of the more convenient methods of doing so is by use of a handheld blow off device.  Given this combination of popularity and convenience, the manufacture and use of air guns is prolific.  They come in all shapes & sizes, and can be made simply and cheaply.

Simple and cheap is fine, in most cases, for the air gun itself.  The part that the air comes out, however, can make all the difference in the world when looking at the cost of operation, environmental effects, and the ability to use the device safely:

  • Cost of operation: the simplest design of an air gun is a trigger device that starts & stops the flow of compressed air through an open discharge.  Throttling this down through a narrow passage increases the velocity of the air flow, making for a more powerful blast of air.  Thing is, this still uses a LOT of compressed air to create that powerful blast…much more than an engineered product. 
  • Environmental effects: By this, I mean noise.  Air guns with a simple open discharge can be LOUD – over 100 dBA in many cases.  It’s been well documented, for a long time, that high noise exposure is bad for operators’ health…and not just in the obvious manner of hearing loss.  Among these other effects are high stress, hypertension, and sleep disorders.
  • Safe use: Open ended blow offs are in violation of OSHA’s directive 1910.242(b,) which regulates the use of compressed air for cleaning purposes.  The big hazard is dead-ending the device into your body…the pressurized air can literally tear your skin open, and inject itself inside.  This creates a dangerous and often life-threatening condition known as an embolism.
Thumb guns are a perfect example of the above mentioned “popularity and convenience.”  They can be made efficient, quiet, and safe by replacing the open end discharge fitting with an engineered product like the EXAIR Super Air Nozzle.  Chip Shields provide additional protection for blown back particulate as well.

EXAIR Corporation offers a diverse line of Safety Air Guns that address all three of these items:

  • Our Super Air Nozzles use a smaller amount of compressed air flow to entrain an enormous amount of “free” air from the surrounding environment to generate a resultant high volume, high velocity air flow.  So you get the same job done, using less compressed air.
  • Another benefit to their specific design is that the entrained air forms a boundary layer that attenuates the sound level of the primary flow, resulting in extraordinarily quiet operation, while still producing a very usable air flow.
  • And…they’re fully compliant with OSHA  because they can’t be dead ended.


If you’d like to talk about efficiency, sound level reduction, and safety in regard to your use of compressed air (hand held or other,) Please Call Us.

<<CLICK HERE>> to visit our website


Vivek Engineers
#22, 1st Floor, 1st Cross, Adj. to IIMB Compound, Bilekahalli Indl. Area, 
Bannerghatta Road, Bangalore - 560 076 
Ph : 080 -  2648 1309, 4170 1145.
Mob : 097404 39220






    



Friday, 4 September 2020

Cold Gun Replaces Inefficient and Ineffective Open Pipe

In any machining operation, tool wear is an inevitability. Cutting tools heat up due to friction and this heat contributes to premature tool wear. As tooling wears, poor tolerances and dimensional inaccuracy are common. Additionally, as the cutting edge dulls increased cutting force is required which further increases the amount of heat generated and exacerbates the problem.

A metalworking company on replacing several open-pipe blowoffs on their CNC machines with EXAIR Cold Guns. The open pipes were not effective at keeping the tooling cool, but did a decent job of blowing away chips. Premature tool wear was leading to increased downtime and slowing production as they were frequently having to replace the tooling. Not to mention, these blowoffs were extremely loud and forced anyone on the shop floor to be wearing in-ear and over-the-ear hearing protection.

Each of their CNC machines had one open-line coolant hose or similarly sized open tube blowing compressed air onto the tool. Temperatures in the facility get fairly warm in the summer and this was having little to no impact. They didn’t want to deal with the mess that comes along with coolant, so they looked to EXAIR for a solution. They ended up installing (1) 5215 Single Point Cold Gun System for trial on one of their machines.

Immediately they noticed the reduction in sound as the Cold Gun operates at just 70 dBA, but they also noticed a 20% reduction in tool wear compared to the open-air lines after a short time in operation. It didn’t entirely eliminate the need for hearing protection as there are other processes occurring, but it did lower it to a point that they weren’t forced to use both in-ear and over-the-ear protection.

EXAIR’s Cold Gun was a Product of the Year finalist in 2007. Using only a source of compressed air, the Cold Gun and High Power Cold Gun produces a stream of clean, cold air 50° (28°C) below your compressed air supply temperature. The Cold Gun is very quiet at only 70dBA and has no moving parts to wear out. Just supply it with clean, dry compressed air and its maintenance free!

The Cold Gun has been preset to achieve maximum refrigeration. This prevents the Cold Gun from freezing up during use and optimizes the gun’s cooling capacity. The Cold Gun is an ideal alternative to messy and expensive coolant mist systems. It eliminates the cost of purchase and disposal of cutting fluids as well as worker related health problems from breathing airborne coolant or slipping on wet floors. Replacing a coolant-based system also eliminates the need for secondary cleaning operations after milling or drilling.



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Vivek Engineers
#22, 1st Floor, 1st Cross, Adj. to IIMB Compound, Bilekahalli Indl. Area, 
Bannerghatta Road, Bangalore - 560 076 
Ph : 080 -  2648 1309, 4170 1145.
Mob : 097404 39220