Thursday, 6 January 2022

Static Season is in Full Swing, Super Ion Air Knives can Remove the Shock!

 

The Gen4 Super Ion Air Knife is a powerful static eliminator that prevents jamming, tearing, shocks and dust build up by neutralizing static and blowing away the debris.

They combine the quiet and efficient Super Air Knife with the compact design of the rugged Gen4 Ionizing Bar resulting in a total solution to remove static electricity from plastics, webs, sheet stock and other product surfaces. Removing the static helps reduce or eliminate the process issues that the static electric causes, allowing for greater production speeds, improved product quality and a cleaner product. Some of the issues static causes include, dirt and dust buildup on surfaces, misreads for sensors, poor quality from ink jets, poor print quality on printed surfaces, and personnel getting shocked.

The Gen4 Super Ion Air Knife floods an area or surface with static eliminating ions. With a uniform airflow across its length, misalignment to critical surfaces like webs is avoided.  The force can be adjusted from a light breeze, to a full out blast of air. The Gen4 Super Ion Air Knife is electrically powered, is shockless and has no moving parts.

How It Works

How The Gen4 Super Ion Air Knife Works

In the diagram above, compressed air flows through an inlet (1) into the plenum chamber of the Gen4 Super Ion Air Knife. The flow is directed to a precise, slotted orifice. As the primary airflow exits, it creates a uniform sheet of air across the entire length, pulling in in surrounding air (2). An electrically powered Gen4 Ionizing Bar (3) fills the curtain of air with positive and negative charges. The air stream delivers the static eliminating ions to the product surface (4) where it instantly neutralizes static and cleans off dust and other particulates.

The Gen4 Super Ion Air Knives are powerful tools, and very quickly dissipates 5kV of static even at low compressed air supply pressures. At 5 PSIG, only 3.7 SCFM (0.3 BAR, only 105 SLPM) of compressed air per foot of length is required!!  Sound levels are also very low, resulting in quiet operation.

Added Features –

  • Compressed Air Inlets are provided on each end and the bottom of the Super Air Knife
  • Thicker shims can be installed easily if more force is needed.
  • Emitter points are durable stainless steel
  • The high voltage cable is armored to resist cuts and abrasion, and has integral grounding.  Threaded bayonet connector is fully assembled and ready to use
  • Electromagnetically shield cable protects sensitive electronics
  • Gen4 Ionizing Bars and Power Supplies are UL Component Recognized to U.S and Canadian safety standards and are CE and RoHS compliant
  • Power Supplies are 115/230 VAC selectable and come with 2 or 4 outlets
  • Standard lengths from 3″ to 108″ (76mm to 2743mm) are offered, and custom lengths are available to meet your process needs

Successful applications include web cleaning, pre-paint dust removal, shrink wrapper machinery, printing equipment, package cleaning and bag opening/filling operations.

If you have questions about Gen4 Super Ion Air Knives, other types of Static Elimination products,  or any of the 16 different EXAIR Intelligent Compressed Air® Product lines, 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






    





Saturday, 23 October 2021

Neutralizing Static in the Printing Industry

 

Cooler temperatures are right around the corner which can lead to low humidity and in turn, static electricity that can wreak havoc on manufacturing processes. One industry that deals with this the most is printing and paper manufacturers. Watch a video on how the Super Ion Air Knife can eliminate static in printing processes and keep operations running smoothly.
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, 18 October 2021

Chip Trapper Overview

We all know the drill, you want to run your coolant for as long as possible because that liquid is not cheap! Especially if you have several machines or even hundreds! But the results of running them longer than you should often stink, (pun intended) they turn sour, the lubrication properties start to diminish and you do not get the benefits you once got! Not to mention chips and small fines (which the stinky bacteria collect upon) can start to clog the system up. Here at EXAIR we had the same problem in our machine shop, so we designed the EXAIR Chip Trapper and use them to this day!


There are some machines which are capable of cleaning the tramp oil and removing any chips or shavings, but these tend to be very expensive and not very effective. Exair tested a few different methods here at EXAIR in  machine shop. As a result of these tests Exair determined that the best foot forward would be to develop something themselves. Enter the EXAIR Chip Trapper. Using either a standard or High Lift Reversible Drum Vac to provide the vacuum source, the Chip Trapper is capable of filling or emptying a 55 gallon drum in less than two minutes. It is able to pick up both the liquid coolant as well as any chips or shavings that are suspended in the coolant. The liquid is forced through a filter bag inside of the drum which contains any solid materials while allowing the coolant to filter out into the drum. Switching the knob on the Reversible Drum Vac and the directional flow valve to empty will allow the clean coolant to be pumped back out of the drum and reused.

Here is a great overview video of the Chip Trapper Set up and operation!


The Chip Trapper is available in either 30, 55, and 110 gallon systems. It’ll also come with (2) 5 micron filter bags, other filter bags are also available ranging from 1 micron up to 200 micron filtration. Using a simple detergent, the filter bags can be washed out, cleaned, and reused multiple times. With no motors or impellers to clog or wear out, as well as no electricity requirement or shock hazard. 



 

Saturday, 16 October 2021

Empty and Fill Machine Sumps with the Reversible Drum Vac Systems

EXAIR has a variety of Industrial Housekeeping products for your specific applications. Let’s explore the capabilities of our Reversible Drum Vac (RDV). The RDV is a safe, maintenance free system and its purpose is to recover liquids, oils sludge and chips from machine sumps. Since it is reversible, it will also fill your sumps from a fresh drum of machining fluids. This system does not require electricity and runs on compressed air. The RDV is maintenance free as it has no moving parts.

The RDV comes in 2 models which includes a “High Lift” version of the RDV and creates a maximum lift up to 15 feet of water column. The RDV comes in 4 capacities of 5, 30, 55 and 110 gallon drums while the High Lift comes in 30, 55 and 110 gallon drums. Let’s now focus on the RDV and the options for purchase.


The first thing to consider when purchasing your RDV is the capacity which I just mentioned of 5, 30, 55 and 110. Once you decided the capacity we have 3 models to choose. The Model 6196 is your basic model and comes with the vacuum unit, stand pipe, vacuum hose and aluminum wand. It is the basics of what you need to empty and fill your machine sumps.

The model 6296 is the same as the 6196 but also includes drum dolly, ABS spill recovery kit, tool holder and all tools.


The model 6396 includes everything as described with the Model 6296 but also includes the drum, drum dolly, upgrade to heavy duty aluminum tools, ABS spill recovery kit, tool holder and air hose.


Kindly contact us for more details.


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, 27 August 2021

Super Air Amplifiers: Evacuation of Smoke or Fumes


 In the pneumatic industry, there are two types of Air Amplifiers.  One type will amplify the inlet air pressure to a higher pressure.  The other type uses the inlet air pressure to amplify the air volume.  EXAIR manufactures the volume type called the Super Air Amplifiers™. 

This change in air volume is called the amplification ratio.  So, what does this mean?  The definition of ratio is the relation between two amounts showing the number of times one value is contained within the other.  For the EXAIR Super Air Amplifiers, the ratio is the value that shows the amount of ambient air that is drawn within the compressed air.  The higher the ratio, the more efficient the blowing device is.  The EXAIR Super Air Amplifiers can reach amplification ratios up to 25 to 1.  This means that 25 parts of ambient “free” air is introduced for every 1 part of compressed air. 

Why an EXAIR Super Air Amplifier?  Like a fan, they are designed to move air.  But fans use motors and blades to push the air toward the target.  The fan blades “slap” the air which creates turbulent air flows and loud noises. The Super Air Amplifiers do not use any blades or motors to move the air.  They just use a Coanda profile and a patented shim to create a low pressure to draw in the ambient air.  In physics, it is much easier to pull than it is to push.  The process of pulling air through the Super Air Amplifiers make them a more efficient, uniform, and quiet way to blow air. 


Super Air Amplifier – flow region
To show the power of the Super Air Amplifier, we have a video of a model 120022.  In the video, oil is being heated to generate smoke, and the Super Air Amplifier is placed in the center of an exhaust pipe.  This demonstration was for a customer that was looking to evacuate vapors from an enclosed area.  Other applications would include welding smoke, ventilation, exhaust tank fumes, and dust collection.  You can see when the Super Air Amplifier is turned on and in operation in the video below. 

EXAIR manufactures and stocks five different sizes ranging from ¾” (19mm) up to 8” (203mm) in diameter.  Some of the benefits that the Super Air Amplifiers have is the inlet and outlet can be ducted for remote positioning.  They are very compact and can fit into tight places like the exhaust pipe above.  They do not have any moving parts to wear or need electricity to run.  They only need clean compressed air to operate; so, they are maintenance-free.  Another unique feature of the EXAIR Super Air Amplifier is the patented shim which optimizes the low-pressure to draw in more ambient air.   As an added bonus, they are OSHA safe and meet the standards for noise level and dead-end pressure. 

With the today’s cost to make compressed air, it is important to use it as efficiently as possible.  The EXAIR Super Air Amplifiers have the ability to give effective blowing to remove debris, dry parts, transport material, cool objects, and clear smoke without using a large amount of compressed air. |

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, 19 August 2021

6 Important Factors when Choosing a Safety Air Gun


 

If you look at operating costs alone, compressed air can be just about the most inefficient method there is for cleaning parts. If you just look at the risks, it’s potentially very dangerous too. Don’t even get me started on the insufferable noise it can make.

For cleaning parts, most folks are familiar with the use of an air gun. You can find the simplest of these in many industrial settings: a valve (often in the form of a handheld trigger device) fitted with a nozzle of some sort (often in the form of an open ended tube, pipe, or fitting to focus or direct the air flow). These have all three of the “downsides” I opened this blog with. Of course, these concerns can be mitigated to a high degree by using the right tool for the job. That’s where engineered products like EXAIR Safety Air Guns come in. Let’s look at how we can address these three “downsides”:

Efficiency: This is all about compressed air consumption. In the simplest of air guns mentioned above, consumption is only limited by the passages in the valve (or trigger) and the discharge fitting…and those limits are usually negligible. Modifying the ends (see examples below) to focus the air flow usually has minimal effect, because you’re not appreciably changing the total cross sectional area of the discharge opening:

Here are a few modified thumb trigger air guns that were sent in for Efficiency Lab testing. Left to right, compressed air consumption at 80psig supply pressure was 34.2 SCFM, 30.9 SCFM, and 28.2 SCFM. For comparison (more on this later,) EXAIR Model 1210 Soft Grip Safety Air Gun uses only 14 SCFM and generates a very similar flow pattern.

Safety: Remember learning about kinetic and potential energy in grade school? Well, when you compress air to 100psig, fitting all that air into a much smaller space creates a TREMENDOUS amount of potential energy:


The block on the left represents a cubic foot of air at atmospheric pressure. The one on the right represents how much space the first one takes up when compressed to 100psig. The energy imparted by this process HAS to be handled with care.

One problem with the thumb guns above is, if you were to jam into the palm of your hand and pull the trigger, a large component of that potential energy (pressure) turns into kinetic energy (force)…more than enough to break the skin and cause a potentially fatal condition known as an air embolism. In the United States, OSHA (Occupational Safety and Health Administration) regulates compressed air devices used for cleaning purposes. All EXAIR Safety Air Guns comply with Standard 1910.242(b) by providing a relief path to ensure that it cannot be dead ended, and thus never create over 30psi measurable at the outlet).


EXAIR Super Air Nozzles cannot be dead ended, ensuring the outlet pressure won’t reach OSHA limits, regardless of supply pressure.

Noise: Another problem is, another component is turned into sound pressure…discharging air from a direct opening is quite loud. OSHA standards address these with limitations on outlet pressure and sound level. All EXAIR Safety Air Guns comply with Standard 1910.242(b), which limits the outlet pressure (by providing a relief path to ensure that it cannot be dead ended, and thus never create over 30psi measurable at the outlet) and all but our largest Super Blast Safety Air Guns comply with Standard 1910.95(a) limits for continuous 8 hour sound level exposure.

Which brings us to the topic of this blog: How exactly did THEY (our customer who used to use the thumb guns above) select the right Safety Air Gun, and how can we apply that to getting the right Safety Air Gun for YOU?

These steps aren’t all-inclusive, and they don’t necessarily need to be followed in order, but if you call an EXAIR Application Engineer about selecting a Safety Air Gun, here’s what we’re gonna talk about:

Ergonomics: We offer five distinctive styles of Safety Air Guns:


From small part cleaning by hand, to wide area blowoff, and all points in between, EXAIR has a Safety Air Gun for most any application.

Our thumb gun user (as I alluded to above) chose the Model 1210 Soft Grip Safety Air Guns (top right). They had a number of typical industrial applications where the operators had the parts or surfaces to be blown off right in front of them. They liked the integral storage hook and rubberized hand grip, but the VariBlast Compact (top middle) or Heavy Duty Safety Air Guns (bottom left) were also considered. The VariBlast Precision (top left) and Super Blast Safety Air Guns (bottom right) were too focused or more powerful, respectively, than needed.

Airflow pattern: Honestly, I could make a good case for this being the first consideration. Selection of any blowoff product – be it an Air NozzleAir AmplifierAir KnifeAir Wipe, etc., will largely depend on the size and shape of the airflow.


    variety of airflow patterns…and effective distances…are available from EXAIR’s comprehensive line of Super Air Nozzle products.
    • For the most precise, focused blowoff, our Atto Super Air Nozzle (top left) is a great choice. It’s available on:
      • VariBlast Precision Safety Air Gun
      • VariBlast Compact Safety Air Gun
      • Soft Grip Safety Air Gun
    • For the typical industrial blowoff applications our thumb gun user had, the Model 1100 Super Air Nozzle (top right) comes on:
      • Soft Grip Safety Air Gun
      • Heavy Duty Safety Air Gun
    • Super Air Nozzle Clusters (bottom left) create higher force & flow, and still keep it in a more concentrated, tighter pattern. They can be installed on:
      • Soft Grip & Heavy Duty Safety Air Guns (4-Nozzle Cluster only)
      • Super Blast Safety Air Gun
    • When stubborn, heavy, and/or LOTS of debris needs to be absolutely, positively blown off RIGHT NOW, our High Force Super Air Nozzles may be just what you need. Our largest; Model 1120 1-1/4 NPT Super Air Nozzle, is shown (above right). The High Force Super Air Nozzles are offered on:
      • Soft Grip or Heavy Duty Safety Air Gun (up to 3.3 pounds of force over a 6.3″ wide area @12″ away)
      • Super Blast Safety Air Gun (up to 23 pounds of force over a 15″ wide area @12″ away)

    Application specific concerns: Everything we’ve discussed so far has involved aiming the blow off stream away from the operator, in the direction the device is aimed. In addition to wide variety of engineered Air Nozzles, EXAIR offers a number of options for these products:

    • We can add 12″ or 20″ extensions, and/or Chip Shields, to our VariBlast Precision Safety Air Guns.
    • VariBlast Compact Safety Air Guns can likewise be fitted with Chip Shields, as well as:
      • Rigid extensions, up to 72″ long.
      • Our Atto Back Blow Nozzles, with extensions up to 36″ long.
    Atto Back Blow Nozzles can blow out recesses or holes as small as 1/4″ in diameter.
    • Soft Grip Safety Air Guns are the most versatile, as far as options go. In addition to Chip Shields, we also offer:
      • Rigid Extensions, up to 72″ long.
      • Stay Set Hoses, for blowoff in hard to reach areas or spaces, in lengths from 6″ to 36″.
      • Back Blow Nozzles for holes with 7/8″ to 4″ diameters, on extensions up to 72″ long.
      • Super Air Scrapers, with extensions from 6″ to 72″ in length.
      • Scrape off, and blow away, stubborn debris with the Model 1244-48 Soft Grip Super Air Scraper.
        • Heavy Duty Safety Air Guns can be fitted with Chip Shields, Rigid Extensions (up to 72″ long) and Back Blow Nozzles as well.
        • We can add 3 foot or 6 foot extensions to our Super Blast Safety Air Guns for extra reach, when necessary.

        If you’re looking for a portable, hand-held compressed air blow off product that’s quiet, safe, and efficient, look no further than EXAIR Corporation’s extensive line of Safety Air Guns. If you’d like to find out more, 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