What is static electricity?
Static electricity refers to the
phenomenon in which electric charges accumulate on the surface of materials, typically due to an imbalance between protons and electrons within atoms. While atoms naturally seek electrical neutrality, disruptions in this balance can occur:
- Positive charge: When an atom sheds an electron, it becomes positively charged, forming a positive ion.
- Negative charge: When an atom acquires an extra electron, it becomes negatively charged, forming a negative ion.
These disparities in charge result in the creation of electrostatic energy, which can interfere with industrial systems and operations.
How is static electricity generated?
During numerous industrial operations, electrostatic charges are formed whenever electrons are transferred between surfaces or materials.
- Through contact and separation:
For example, repetitive contact—such as a cylinder striking a surface—can generate opposing charges on the two interacting elements. - Via friction:
Mechanical processes like materials moving over rollers or conveyors often cause charge buildup through friction. - Induced by nearby charged objects:
Even without touching, a charged object can influence nearby materials, causing localized imbalances. This is particularly hazardous in electronic manufacturing, where even low-voltage static can damage sensitive components. - Generated during air-blowing processes:
Blowing compressed air during cleaning requires special care. If the air isn’t properly filtered and dried, or if humidity is low, static charges can form on target surfaces, increasing contamination risks.
Risks of static electricity in industrial applications
Static build-up can significantly affect industrial productivity and safety, especially as measured by
OEE (Overall Equipment Effectiveness), which evaluates:
- Machine availability:
Electrostatic forces can cause materials to stick or repel one another, leading to jams and unscheduled downtimes. - Process performance:
In some cases, machines must operate at reduced speed to limit charge accumulation, affecting production throughput. - Product quality:
Static energy may attract dust or airborne particles, or even damage delicate electronics, leading to quality issues and increased product rejections.
The issues above are often grouped as:
Macroscopic static effects
Typically found in plastic and polymer handling, macroscopic statics impact machinery and process flow. Associated challenges include:
- Faulty cutting or welding
- Blocked winding mechanisms
- Feeding malfunctions
- Shrink-wrap irregularities
- Misalignment during handling
Microscopic static effects
More common in precision electronics or automotive parts manufacturing, where surface purity is vital. Issues can include:
- Paint defects (e.g., micro-pores)
- Plastic contamination
- Injection molding imperfections
- Fractures in delicate components
- Electrostatic Discharge (ESD), leading to either immediate or latent failure in electronic parts
Both types of static can lead to production inefficiencies, compromised quality, and even safety hazards—like ESD to operators or, in extreme cases, fire or explosion risk due to charge accumulation.
How to control and avoid static electricity in industrial applications?
To effectively manage and avoid static electricity, several approaches can be used:
1. Measurement tools
As static charge is invisible, the first step is detection. SMC offers
electrostatic sensors to help identify problem areas and address them efficiently.
2. Grounding systems
Proper earthing is essential to divert unwanted electrical charges away from operators and equipment. All conductive materials should be grounded to ensure safe dissipation.
3. Electrostatic discharge solutions
Different ionization technologies are used depending on the application:
Industries that benefit from Static Control Products
Static control solutions play a critical role in a wide range of industrial applications. The sectors that most commonly benefit from these technologies include:
- Packaging
- Food Processing
- Automotive
- Electronics
- Machine Tools
- Plastics
- Glass Manufacturing
These industries rely on static control to improve product quality, reduce waste, and ensure safety throughout production processes.
Industries that benefit from Static Control Products
Static control solutions play a critical role in a wide range of industrial applications. The sectors that most commonly benefit from these technologies include:
These industries rely on static control to improve product quality, reduce waste, and ensure safety throughout production processes.
How to choose the right Static Control equipment?
Choosing the appropriate static control product requires a clear understanding of your specific application and operating environment. Key factors to evaluate include:
- Type of workpiece
- Level of static charge present
- Distance between equipment and installation point
- Required deionization time
- Process speed
Need assistance finding the right solution? Our experts are here to help—contact us for personalized support.
