Saturday 31 October 2020

How The Cold Gun Works

 

The standard Cold Gun and High Power Cold Gun incorporate a vortex tube to convert an ordinary supply of compressed air (1) into two low pressure streams, one hot and one cold. (For complete information on vortex tube operation, see page 175 of this catalog.) Secondary air is drawn in (2). The Cold Gun's hot airstream is muffled and discharged through the hot air exhaust (3). The cold air (4) is muffled and discharged through the flexible hose (5), which directs it to the point of use. Easy mounting and portability are provided through the use of an attached magnetic base (6).


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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






    

Friday 30 October 2020

Better Quality Thanks To A Super Air Knife

 A regional bakery has opened up production and after months of determining their recipe and icing selection, they still needed some help on getting the glazing level correct on the finished doughnuts. The baked goodness would travel under a waterfall of glazing and several variables would lead to the amount of glazing that would build up/ remain on the doughnut. After testing these variables out the customer still wanted a better coating so they called EXAIR.

The solution, a 30″ 316 Stainless Steel Super Air Knife to mount over the conveyor and blow down the surplus glazing into the catch pan for recirculation.  The variability in force from a gentle breeze up to a forceful, glaze stripping blast, was exactly what the baker ordered.  This setup has been in practice for months now and nothing but positive results have been tasted.
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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






    



Thursday 29 October 2020

Soft Grip Safety Air Guns


 EXAIR's Soft Grip Safety Air Gun is ideal for hours of continuous use without fatigue. The ergonomic design keeps the hand in a comfortable position and incorporates a large trigger that permits operation with one or more fingers. The durable cast aluminum body is suited for rugged industrial use and includes a convenient hanger hook for easy storage.

The inlet is 1/4 NPT. The Soft Grip Safety Air Gun is available with Air Nozzles as shown below for quiet, safe and efficient use of the compressed air supply. Aluminum Extension Pipes and Stay Set Hoses that can reach normally inaccessible areas are available for most models. Chip Shields are available for Soft Grip Safety Air Guns as well. See -CS Model links below. Coiled Hoses with Swivels are available with models indicated below.
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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






    

Wednesday 28 October 2020

Nozzles for Cleaning Inside Hose, Tube, Pipe and More

 


Some applications such as blowing chips or debris out of a pipe or blind hole, it may not be possible to blow forward. The pipe may be too long, making it impossible to push the debris all the way down the pipe or the other end of the pipe may not be open. In either of these scenarios, the Back Blow Nozzle is the right tool for the job. An array of holes around the diameter of the Back Blow Nozzles provides a powerful 360° airflow pattern that will clear out any leftover coolant or chips from the machining process.
EXAIR has three different size Back Blow Nozzles; the 1004SS (M4 x .5), the 1006SS (1/4 NPT), and the 1008SS (1” NPT). The 1004SS is recommended for use on pipes as small as ¼” and up to 1”. The 1006SS can be used for a wide range of pipe sizes, from 7/8” up to 4”. The 1008SS nozzle offers the greatest overall force for stubborn or sticky materials stuck to the inside diameter of the pipe. This nozzle is suitable for use in pipes ranging from 2”-16”. As the Back Blow Nozzle will be blowing chips and debris back out of the pipe towards the operator, it is always recommended that a Chip Shield is used. The strong polycarbonate Chip Shield will keep them safe from flying debris and keep you in compliance with OSHA directive 1910.
All of EXAIR’s Back Blow Nozzles are available with extensions. For the 1004SS we have extensions from 6”-36”, and from 12”-72” for the 1006SS and 1008SS. The Back Blow Nozzle can also be installed on our VariBlast, Soft Grip, Heavy Duty, and Super Blast Safety Air Guns. With such a wide range of available sizes and configurations, we can tackle just about any internal pipe cleaning application. If you have a process in your facility that may benefit from the use of one of these nozzles, Please contact us.
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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 27 October 2020

An Ultrasonic Leak Detector Helps with a Pressure Decay Leak Detector

 


A manufacturing company had a pressure decay leak system to check for leaks in compressed air housings.  Their detector was able to find leaks as small as 0.02 cc/min.  The leak program was designed for recording each housing with a batch/lot number and the corresponding leak data.  If the housing reached or surpassed the leak limit, the part would be marked and quarantined.  The pressure decay leak detector was a sensitive instrument, but it could not tell the operator where the leak was occurring.



How the pressure decay leak detector worked was by pressurizing the housing to a target pressure.  The flow valves would shut, isolating the housing.  After the pressure stabilized, the sensitive pressure sensors would pick up any loss in pressure over time.  If the leak limit wasn’t reached, a green light would indicate a good leak test.  If the limit was reached, a red light would indicate a failed leak test, and the housing would have to be segregated.

The housing design used a head, a bowl, a drain, and a differential pressure gauge.  The leak paths were numerous.  It could be at the drain, between the drain and the bowl, between the head and bowl, at the differential pressure gauge, and even in the casting of the head.  The heads were made from a die-casted aluminum.  If the process was not done properly, porosity could occur in the head.  The leak detector was sensitive enough to find any voids that would allow air to pass through the head casting.  With these many areas of potential leaks, it could be problematic if the reject rate was high.



For the application above, it is important to find where the leaks are occurring in order to create a corrective action.  In order to find the leaks, they purchased a model 9061 Ultrasonic Leak Detector from EXAIR.  Instead of pressure decay, the Ultrasonic Leak Detector uses sound.  Whenever a leak occurs, it will generate an ultrasonic noise.  These noises have a range of frequencies from audible to inaudible.  The frequencies in the range of 20 Khz to 100 Khz are above human hearing, and the Ultrasonic Leak Detector can pick up these high frequencies, making the inaudible leaks, audible.  The model 9061 has three sensitivity ranges and a LED display; so, you can find very small leaks.  This unit comes with two attachments.  The parabola attachment can locate leaks up to 20 feet (6.1 meters) away.  And the tube attachment can define the exact location.  With this application, they used the tube attachment to locate the leaks.  After retesting the failed housings, they found that 80% of the rejects were from a sealing surface.  They were able to replace or repair the o-rings.  10% of the leaks were coming from the drain.  3% of the rejects were leaking at the differential pressure gage.  Both the drains and the pressure gages could be replaced with new units.  7% of the housings had a porosity problem in the head of the housing.  For these, they were shipped back for evaluation to create a modification for a better casting.  The production manager shared with me that an extra vent hole was required to reduce the void.  This was a huge savings for the die-caster and manufacturing plant.

EXAIR Ultrasonic Leak Detector is a great tool.  It can be used in a variety of applications including compressed air systems, bearing wear, circuit breakers, refrigerant leaks, and gas burners to name few.  For the company above, it was a great tool to improve their assembly and testing process for their housings.

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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






    


Thursday 22 October 2020

Vortex Tubes: What is a Cold Fraction?

 Have you ever needed a source of cold air but don’t want to invest in a costly chiller? INTRODUCING Vortex Tubes! Vortex Tubes use compressed air and contain no moving parts to create a cold and hot stream of air from either end of the device. Using the valve located on the hot stream a vortex tube can achieve temperatures as low as -50°F (-46°C) and temperatures as high as 260°F (127°C).

When the vortex tube is supplied with compressed air the air flow is directed into the generator that causes spin into a spiraling vortex at around 1,000,000 rpm. This spinning vortex flows down the neck and wall of the hot tube. The control valve located on the end of the hot tube allows a fraction of the hot air to escape and what does not escape reverses direction and travels back down the center of the tube and exhausts out of the cold end. Inside of the low-pressure area of the larger outer warm air vortex, the inner vortex loses heat as it flows back to the cold end of the vortex and as it exits the vortex expels cold air. The absolute temperature drop that occurs during this process is going to be controlled by the cold fraction of the Vortex Tube and the supply pressure.


The cold fraction is defined as the amount of the inlet supply air that will exit out of the cold end of the vortex tube. An example would be if I had 10 SCFM supplied to a vortex tube with 60% cold fraction, then 6 SCFM would be exiting the cold discharge. Cold based on the amount of air you allow out of the hot end of the vortex tube you can control the temperature drop of the cold air. A smaller cold fraction which only allows a small amount of air to exit the cold discharge will result in a larger temperature drop; and vise versa a larger cold fraction will result in a much smaller temperature drop.


Here  EXAIR has designed the vortex tubes to operate optimally at both a high cold fraction and a low cold fraction. The 32XX series designed to give you the best refrigeration, which means it will work well for cold fractions ~60% – 80%. This will give you a smaller temperature drop with more air flow which allows you to keep things cool much easier. This contrasts with the 34XX series which is designed more optimal performance at lower temperatures; this means the optimal cold fraction would be ~20% to 40%. Cold fractions this low will produce very little air flow but the temperature will be very cold (as low as -50°F). This is useful if you need to get an item down to a very low temperature.

If you have any questions about compressed air systems or want more information on any of EXAIR’s products, give us a call, we have a team of Application Engineers ready to answer your questions and recommend a solution for your applications.

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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






    

Wednesday 21 October 2020

Variety – The Key for Successful Applications No Matter the Conditions


 EXAIR has been manufacturing Intelligent Compressed Air® products since 1983.  In the beginning, the Standard Air Knives and Full Flow Air Knives were very effective at that time.  But as leaders in this market, EXAIR did not want to stop there.  We were able to engineer a more efficient, more powerful, and much safer air knife, the Super Air Knife.  In this blog, I will discuss the features and benefits that the Super Air Knives can offer. 

Bernoulli’s principle explains how a high velocity fluid can generate a low pressure.  The Super Air Knife creates that high velocity air stream to produce a low pressure above and below the opening to entrain ambient air.   What does this mean for you?  It will save you much money by using less compressed air.  The mass of the free ambient air is added into the air stream to give a strong blowing force.  The Super Air Knife has an amplification ratio of 40:1. For every 1 part of compressed air, 40 parts of ambient air is drawn into the blowing air stream.  Ambient air is free, and compressed air is definitely not.  EXAIR was able to engineer a design to use the Bernoulli’s principle to make one of the most efficient air knives in the market place.



As a benefit, they blow a laminar air stream which reduces noise levels and create a consistent force along the entire length.  An even force will give you tighter control for blowing applications which will cut compressed air usage unlike the inconsistent and turbulent air flows caused by drilled pipes, manifolds of nozzles or blower-type systems.  Some other interesting features for the Super Air Knives are that they have a compact design to fit into tight places for blowing and cooling.  The footprint is very small as compared to blower-air knife systems.  They do not have any moving parts to wear or maintenance to do.  They only need clean compressed air to work. 

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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