Mini Cooler Improves Custom Cutlery Production

Vortex Tubes use compressed air to create a stream of cold air and a stream of hot air. As the compressed air enters the unit, it travels through a spin chamber which spins the air at speeds up to 1,000,000 RPM producing temperatures ranging from -50°F to +260°F and providing cooling up to 10,200 Btu/hr. With no maintenance requited and no moving parts, they have become quite popular in large and small scale cooling applications in place of more conventional methods of cooling.

How an EXAIR Vortex Tube Works

EXAIR has incorporated this technology into several different products like our Cabinet Cooler Systems used to cool electrical panels and our Cold Guns commonly used to replace messy mist systems in tool cooling, milling and machining operations. For smaller scale processes we offer our Mini Cooler System which provides a 50°F temperature drop from the compressed air supply temperature and 550 Btu/hr. of cooling capacity.

I recently worked with a small, custom knife manufacturer who was looking for a way to keep his tooling cool during production. As the blades are made, he uses a small rotary die tool to shape and sharpen the blade. He also makes his own handles out of materials like wood, ceramics or other metals, which get etched with a custom design into the surface. The heat generated during theses processes, causes the tooling to either bend or break completely, resulting in damage to the knife blade and burns or breaks in the wood and ceramic handles. After looking at our spot cooling products online, he familiarized himself with the Vortex Tube technology but with only 12.9 SCFM of air available, he was unsure what product would best fit his application.

With the limited amount of air available, the Model # 3808 Mini Cooler System was the perfect solution. The Mini Cooler uses only 8 SCFM @ 100 PSIG, falling well within the capacity of his current compressor. The integral magnetic base would ensure an easy installation and with the included flexible hose, he could direct the cold air to the needed area.

The Mini Cooler is ideal for small tool and part cooling applications.

For help with your spot cooling needs or to discuss how the Vortex Tube technology could help in your process, contact an application engineer for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

 

Camera Lens Cooling with EXAIR Vortex Tubes in a High Temperature Environment

Connection side of camera lens housing. Dimensions shown are in cm.

A customer in Russia contacted our distributor in Moscow about an application to monitor the flow of melted glass.  In their application, the end user had installed (4) camera “eyes” with thermal insulation to instantaneously measure the melted glass flow.  But, the high ambient temperatures would cause the temperature of the camera lens to slowly increase during operation, eventually resulting in an overheating condition.  This overheating condition rendered the cameras inoperable until they were cooled below a temperature of approximately 40°C (104°F).

What this end user (and application) needed was a suitable solution to cool the lens of the camera to a temperature below 40°C (104°F).  A typical refrigerant based air conditioner wouldn’t work for this application due to space and temperature constraints, as the cameras are located close to the furnace with ambient temperatures of 50°C (122°F) or higher.

What did provide a viable solution, however, were High Temperature EXAIR Vortex Tubes.  Suitable for temperatures up to 93°C (200°F), and capable of providing cooling capacities as high as 10,200 BTU/hr., these units fit the bill for this application.

Full view of the camera lens housing. The camera lens is the portion protruding from the far left of the housing.

After determining the volume of compressed air available for each camera, and after discussing the solution options and preferences with the customer, they chose (4) model BPHT3298 Vortex Tubes, using (1) Vortex Tube for each camera.  The cold air from the Vortex Tube will feed directly onto the camera lens, keeping it cool even in the hot ambient conditions.  This removes lost productivity due to machine downtime, which in turn increases output and reliability from the application process.

High Temperature Vortex Tubes provided a solution for this customer when other options were unable to deliver.  If you have a similar application or would like to discuss how an EXAIR Vortex Tube could solve an overheating problem in your application, contact an EXAIR Application Engineer.  We’ll be happy to help.

 

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Trouble Identifying an EXAIR part? Don’t worry, we’ve got you covered!

3240VT

EXAIR Model 3240H Vortex Tube with Hot Muffler Installed

 

Not a day goes by that we don’t receive a call from a customer that is having trouble identifying an EXAIR part. Due to the robust nature of our Vortex Tubes, they can be installed in applications for several years without any maintenance. When the time comes to expand that line, the labels may have worn off, the unit may be covered in grime or oil, or the personnel that originally ordered the product may no longer be with the company. In any case, one of the Application Engineers here at EXAIR will certainly be able to help!

I recently received an e-mail from a gentlemen in Indonesia who was suffering from that very problem. They had a Model 3240 Vortex Tube installed in a camera cooling application near a boiler. The engineer who designed the project was no longer with the company and they could not determine a Model number or when they had purchased it. They saw the EXAIR sticker, along with our contact information, and reached out for help. Vortex Tube’s come in different sizes, based on the available compressed air supply as well as the level of refrigeration needed. They’re available in (3) different sizes as well as Vortex Tubes for max refrigeration (R style generators) and Vortex Tubes for a maximum cold temperature (C style generators). In order to identify the Model number, you must look on the shoulder of the Vortex Tube generator. On it, there will be a stamp that indicates the generator style that is installed. In this case, the customer stated that there was a “40-R”, indicating to me that he had our Model 3240 Vortex Tube.

Our team of highly trained Application Engineers is here ready to assist you with any needs you may have regarding EXAIR products. With a little bit of investigative work, a quick discussion about the dimensions or a photo; we’re able to identify any of our products. If you’re considering expanding a current line into other parts of your facility, or perhaps adding a new location and need help identifying your EXAIR products; give an Application Engineer a call and we’ll be sure you get the right products on order!

Tyler Daniel

Application Engineer

Twitter: @EXAIR_TD

E-mail: tylerdaniel@exair.com

Cooling Nylon Parts and Brushes with the Adjustable Spot Cooler

A robotics company called last week looking for a recommendation for a cooling device to use in their nylon plastic machining operation. They have a six axis robot, fitted with abrasive brushes, that “cleans” the part profiles as they are being moved from the milling area to the inspection location. The brushes were effective in removing the fines and particulate from the parts but they were starting to experience an increase in the amount of rejects as the brushes were generating heat, causing deformities to the profile.

Their initial thought was to use a liquid type method of cooling but with the parts having some small recesses and cavities that might trap fluid, this wasn’t going to be a reliable option for them. Another area of concern with using an air cooling device, was if the airflow was too forceful, the smaller parts they process may have the potential to “move” while being held by the robotic arm which could scratch or blemish the part.

After further conversation about the process, I recommended they use our Adjustable Spot Cooler in the application. The Adjustable Spot Cooler incorporates a Vortex Tube to produce a cold airstream as low as -30°F with an ambient air supply temperature. Using the temperature control valve, they can easily adjust the temperature drop and the volume (SCFM) of air being exhausted, to “dial” in the device to provide an adequate level of cooling while controlling the outlet flow to not disrupt the hold on the part itself. With the integral magnetic base and flexible tubing, they could easily mount the unit to the arm of the robot while directing the cold air to blow across the brushes and the part to keep them cool.

Model # 3825 Adjustable Spot Cooler System includes 2 extra generators to allow for more or less cooling capacity and airflow.

EXAIR offers a wide variety of spot cooling products for many different processes and uses. For help selecting the best option to fit your need or to discuss another product, give me a call, I’d be happy to help.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

 

 

 

 

A Cold Gun Increase Speed for a Reel Manufacturer

When it comes to die stamping, friction generates heat.  Heat can be a big cause in slowing production and decreasing tool life.

Reel Film

A reel manufacturer was seeing the effects of the heat in their process.  They had a stamping machine that was creating sprocket holes in the outer edge of a 35mm film.  These holes are used for advancing the reel strip through printers, projectors, and processing machines.  They had to be particularly careful, as film materials warp easily with heat.  Some of us remember the film reels that would bubble and burn out when the film stopped in the projector.  (I am giving away my age a bit).  So, speed was critical as they did not want to create any quality issues.

They were intrigued with the EXAIR Vortex Tubes as it can generate cold air by only using compressed air.  Vortex Tubes do not use refrigerants or have any moving parts.  They are very compact and can fit into tight places.  If they could reduce the temperature in the stamping process, then they could speed up production.

Compact Vortex Tube

With the Vortex Tubes, EXAIR adds accessories to help with installations for different applications.  For this customer, the Cold Gun Aircoolant System was the best product to deliver the cold air.  I recommended the model 5315 Cold Gun System.  This product generates 1000 BTU/hr of cooling power, and it has a Dual Point Hose Kit to target both sides of the film reel.  It includes a magnetic base to securely position it on the stamping machine, and two 1” flat nozzle ends to attach at the end of the Dual Point Hose Kit.  These flat nozzles would help to direct the cold air in between the two stamping plates.   They were able to keep the film reel and the die stamp cool as they sped up their operation.  Even with the additional speed, they also noticed that the die stayed sharper 20% longer before they had to rework.

Cold Gun with Dual Hose Point

If you believe that heat is slowing down your system, EXAIR may have a product to keep it cool.  With the customer above, heat was a “reel” problem.  With the Cold Gun System, we were able to increase their productivity and decrease their downtime.  You can contact an Application Engineer to discuss your application if you believe that temperature is affecting your process.

 

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

 

Photo: Movie Reel Film Cinema by JanBaby.  Creative Commons CC0 Public Domain.

Music And The Mini Cooler

Recently, EXAIR Corporation offered CPR (cardiopulmonary resuscitation) training to employees. I already carry certification, so I held down the fort while some of the other Application Engineers received this training. As a middle aged man, I have to admit that my interest in my co-workers’ abilities to respond to a matter of this nature is not entirely unselfish.

One of the key parts of CPR training is the rate of the chest compressions. While most people couldn’t accurately replicate 100 beats per minute on demand, almost everyone is familiar enough with some popular songs with a rhythm close to that.  The song they always bring up in CPR training is “Stayin’ Alive” by the Bee Gees. Depending on how you feel about disco, another option is “Another One Bites The Dust” by Queen. Pro tip: it might be considered bad form to sing that one out loud while performing CPR.

Speaking of music, while I was holding down said fort during this morning’s training session, I had the pleasure of assisting a caller in the music business: a piano restoration & tuning professional. A frequent job for them consists of resetting tuning pins, which requires drilling numerous small holes (a grand piano can have as many as 250) into a hardwood board. They’re pressed in, so it’s critical that they fit the newly-drilled hole precisely. If the drill bit gets too hot, it can expand in diameter, making the hole ever-so-slightly bigger than it should be. The heat can also cause the surface of the hole ID to glaze. Both of those things can cause problems with the pin fitting securely in the hole.

The EXAIR Model 3808 Mini Cooler System was an ideal solution – it’ll keep the drill bit cool & clean with a constant stream of cold air. It’s compact and quiet, and only uses 8 SCFM @100psig…well within the capacity of many smaller air compressors.

If you’d like to “get in tune” with a spot cooling solution, I can help…call me. Oh, and in case you wanted to know which song with about 100 beats per minute I’d use for CPR:

Russ Bowman
Application Engineer
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EXAIR Cabinet Cooler System Meets High Demands Of Sea Duty

I joined the Navy, right after high school, to get out of Ohio, see the world, and never come back. “My recruiter said” (if you are considering military service, those can be famous last words, just so you know) that I would be a good candidate for Nuclear Power School, so I took the test. As a math & science nerd scholar, I qualified for admission easily.  About halfway through Nuke School, I volunteered for submarines.  My decision was based in no small part on the sea stories of our instructors, the strong reputation of better food, and my deep appreciation for the movie “Operation Petticoat.”

Upon graduation, I was assigned to a new construction Trident submarine.  I did not see the world…I saw the Electric Boat shipyard in Groton, Connecticut, and Naval Submarine Base King’s Bay, Georgia.  Hilarity occasionally ensued, but never in the context of that movie I so adored.  I moved back to Ohio (on purpose) soon after my enlistment was up.  The food WAS good…I can unreservedly vouch for that.

In the new construction environment of the shipyard, I became quite familiar, and developed a deep respect for, the high level of attention paid to the materials and workmanship that a seagoing vessel demanded…not to mention, one with a nuclear reactor on board.  Reliability and durability are obviously key factors.

I had the pleasure recently of assisting an electrical contractor who was looking for a cooling solution for a new Variable Frequency Drive enclosure installation on a cement barge.  The ship’s engineer (a Navy veteran himself) had told the contractor that his priorities were reliability, durability, and dust exclusion.  He couldn’t have made a better case for an EXAIR Cabinet Cooling System.

Based on the specified heat load of the VFD, the size of the enclosure, and its location, a Model 4380 Thermostat Controlled NEMA 12 Cabinet Cooler System, rated at 5,600 Btu/hr, was specified.  This equipment is internal to the ship; had it been exposed to the elements, a NEMA 4X system would have been presented.

Up to 2,800 Btu/hr cooling capacity with a single Cabinet Cooler System (left) or as much as 5,600 Btu/hr with a Dual system (right.)

EXAIR Cabinet Cooler Systems have no moving parts to wear, no electric motor to burn out, and no heat transfer surfaces (like a refrigerant-based unit’s fins & tubes) to foul.  Once it’s properly installed on a sealed enclosure, the internal components never see anything but cold, clean air.

If you have a need to protect an electrical enclosure in aggressive environment, give me a call.  With a wide range of Cabinet Cooler Systems to meet a variety of needs, we’ve got the one you’re looking for, in stock and ready to ship.

Russ Bowman
Application Engineer
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