Two weekends ago I had the pleasure of flying out to meet my friend in Colorado Springs and ski the weekend at Breckenridge. As an avid skier Breckenridge has been one of the resorts I have been wanting to ski since I started skiing out west. The weather was amazing and I couldn’t ask for better; the Saturday blue skies and cool breeze followed up by a Sunday of snow fall. The Trip was a dream come true. Breckenridge is specifically known for having high winds that howl across the peaks that stand at a max of 12,998 ft. above sea level. These chilling winds would freeze just about anyone if you aren’t dressed prepared for them as they blow right in your face on the lift. As I was sitting on the lift with these cold winds blowing in my face it brought to mind EXAIR’s Vortex Tubes, Cold Guns, and Cabinet Coolers.
EXAIR’s Vortex Tubes and similar products provide everything from a cool blast of air to a frigid breeze to cool off various parts and products. In a lot of smaller milling and grinding applications the Cold Gun has been used as a replacement to costly coolant-based alternatives. Vortex tubes have been used in cooling applications since 1945 and assist in everything from stress testing electronics to cooling down plastic parts during ultrasonic welding.
If you have any questions or want more information on how we use our vortex tubes to improve processes all over industry. Give us a call, we have a team of application engineers ready to answer your questions and recommend a solution for your applications.
Cody Biehle Application Engineer EXAIR Corporation Visit us on the Web Follow me on Twitter Like us on Facebook
A manufacturing plant contacted EXAIR to help them with a “sticky” situation. This company extruded PVC tubes that would be used as fuel lines on small engines. Plasticizers are typically used to add flexibility to plastic materials. For the PVC material above, a plasticizer was added to make it softer and more elastic. The issue that they saw was the outer surface of the tubes were tacky from the plasticizer and heat which made it difficult to handle in packaging the tubes.
This company extruded many different diameters, but they wanted to target their most difficult size, the smallest tube. The dimensions were given as 0.187″ (4.7mm) O.D. by .0934″ (2.4mm) I.D., and the feed rate was close to 4 feet/min (1.2 meter/min). The problem area that they explained was at the end of the production line where the extruded tubes were cut by a blade cutter into 12” (305mm) lengths. The tubes would then fall into a collection bin for batch processing. Since the collection bin was setup at a slight upward angle, they wanted the tubes to gather toward one end of the bin. Since the tubes were still hot and sticking to each other, the operators had to individually handle each tube which was counterproductive and time-consuming. After our discussions, I suggested that cold air could harden the PVC tube enough by removing heat and help to “set” the platicizer. Since they manufactured different sizes and feed rates, we needed to have adjustability as well in our cold air device.
One of our most versatile spot cooling instruments is the EXAIR Adjustable Spot Cooler. This system uses the Vortex Tube technology to convert compressed air into a cold air stream without any moving parts, refrigerants, or motors. The Adjustable Spot Cooler is a low-cost, reliable, maintenance-free way to give spot cooling for a myriad of industrial applications. For this customer, this product gave them the versatility that they were needing.
EXAIR stocks these units with either a single or dual point hose kit, a magnetic base, a filter separator, and two additional generators. The control valve at the end of the unit adjusts the output temperature down to -30 oF (-34 oC) with a turn of a knob. The generators are specifically engineered to control the amount of compressed air that is used. Both types of controls will allow this customer to “dial in” the correct cooling capacity for the operation. The filter separator included with the system will clean the compressed air to keep the unit and the product free of dirt and debris. The magnetic base which this customer really liked makes the Adjustable Spot Cooler portable for use in different areas.
I recommended the model 3925 Adjustable Spot Cooler because it had the dual point hose kit to blow cold air on both sides of the tubes. Since this company had different tube diameters and thicknesses, adjustability was very critical. If the tubes got too cold, cracks could occur from the blade cutting machine; and, if the tubes were too warm, the tackiness on the surface of the tube would remain. Once they installed the Adjustable Spot Cooler, this company was able to increase their packaging line for the different size PVC tubes. Now the operators could reach into the collection bin and grab many aligned tubes instead of individually separating and sorting.
If you have a “sticky” situation, the EXAIR Adjustable Spot Cooler may be a product for you. The company above was able to have their tubes slide together in the collection bin. Many applications could be improved by adding cold air. And, if you have a similar situation, an Application Engineer at EXAIR will be happy to discuss a solution.
A manufacturer of automotive power transmission shafts was experiencing frequent failure of high pressure plastic rollers on their spin tester. There are four rollers in a 90° array that center the shaft during spin testing. They exert a pressure of around 1,500psi onto the shaft while it’s rotating at 1,000rpm. This generates enough heat to actually melt the rubber coating on rollers, which means stopping testing (which holds up production) while they change out the rollers. Just for it to start all over again.
Thing was, they wanted to mount the Adjustable Spot Coolers where they could have access to the Temperature Control Valve, but the cold air Hose Kit wouldn’t reach the shaft. So they got a couple of extra sections of the cold air hose…they needed one section of the ‘main’ (shown circled in blue, below) to reach into the test rig’s shroud, and two sections of the ‘branch’ (circled in green) to reach to each roller.
Now, adding too much hose length will start to put line loss on the cold air flow, and it will pick up heat from the environment. But if you just need that extra foot of hose to get the job done, this generally works just fine. The extra foot or so they’ve added (5″ to the main and 6″ to each branch) has solved their problem…they haven’t had to replace a roller since the Adjustable Spot Cooler Systems were installed.
One of our more versatile cooling devices is the Adjustable Spot Cooler. The temperature can be changed from ambient down to -30 deg. F (-34 deg. C) with a turn of a knob. In addition to this, the cooling capacity can be modified as well by simply changing the generator. In this video, I will show you how to do this.
The Adjustable Spot Cooler is a low cost, reliable , maintenance free way to provide spot cooling to a myriad of industrial applications. Simply turn the knob, and the temperature can be changed to suit the needs of the process. The Adjustable Spot Cooler delivers precise temperature settings from -30°F (-34°C) to room temperature.
It can produce temperatures form -30°F to +70°F (-34°C tp +21°C)
Parts included for flow rates of 15, 25 and 30 SCFM (425, 708, 850 SLPM.) The unit comes from the factory set at 25 SCFM (708 SLPM)
It can produce refrigeration up to 2,000 BTU/hr (504 Kcal/hr.)
A swivel magnetic base allows for easy mounting and portability, you can move it from machine to machine as needed. The flexible cold air outlet tubing holds its position and is easy to aim. Most importantly, there are no moving parts or CFC’s, ensuring maintenance free operation.
The Adjustable Spot Cooler incorporates a vortex tube to convert a supply of compressed air (1) into two low pressure streams, one hot and one cold. With the turn of a knob, the temperature control valve (2) allows some hot air to flow through a muffling sleeve and out the hot air exhaust (3). The opposite end provides a cold air stream (4) that is muffled and discharged through the flexible hose, which directs it to the point of use. The swivel magnetic base (5) provides easy mounting and portability.
The Adjustable Spot Cooler can produce a wide range of air flows and temperatures as determined by the temperature control valve knob setting and the generator installed. The generator controls the total SCFM (SLPM) of compressed air consumption, and is easy to change. From the factory, the 25 SCFM (708 SLPM) generator is installed, producing up to 1,700 BTU/hr (429 Kcal/hr) of cooling. For less cooling, the 15 SCFM (425 SLPM) generator can be installed, providing up to 1,000 BTU/hr (252 Kcal/hr) of cooling. And for more cooling, the 30 SCFM (850 SLPM) generator can be installed, providing up to 2,000 BTU/hr (504 Kcal/hr) of cooling.
Two (2) Systems are available as shown below, and include the 15 and 30 SCFM (425 and 850 SLPM) generators, a filter separator, and either a single or dual point hose kit.
Adjustable Spot Cooler Systems
If you have questions about the Adjustable Spot Cooler or any of the 16 different EXAIR Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.
A little while back, I worked with a large eyeglass manufacturer on a sunglass lens cooling application. In their setup, they were dry cutting film-coated lenses with a router and after the lenses are cut, they are passed through several different rinse cycles and inspected for scratches or other damage. They were seeing a high number of reject parts and determined that the heat being generated by the tooling, was causing the irregularities. In an effort to alleviate the condition, they used a section of open flexible tubing to blow compressed air at the bit, which helped a little, but they were still concerned with the amount of scrap material.
I recommended they use our Model # 3825 Adjustable Spot Cooler System in the process. The Adjustable Spot Cooler incorporates a Vortex Tube to provide a temperature drop from the incoming supply air temperature. Using the temperature control valve, the exhausting air temperature and flow can be adjusted to fit the application. The system includes a flexible hose to focus the cold air to the desired area until re-positioned. The system also features a magnetic base that allows for easy mounting. By incorporating the filter separator included in the system, they can remove any moisture and/or contaminants in the air supply, relieving any concern with contamination or damage to the part.
If you have a cooling application you’d like to discuss or for help selecting the best product to fit your need, give me a call at 800-903-9247.
I had the pleasure of discussing a spot cooling application with a customer this morning. He wanted to get more flow from his Adjustable Spot Cooler, but still keep the temperature very low. He machines small plastic parts, and he’s got enough cold flow to properly cool the tooling (preventing melting of the plastic & shape deformation) but he wasn’t getting every last little chip or piece of debris off the part or the tool.
After determining that he had sufficient compressed air capacity, we found that he was using the 15 SCFM Generator. The Adjustable Spot Cooler comes with three Generators…any of the three will produce cold air at a specific temperature drop; this is determined only by the supply pressure (the higher your pressure, the colder your air) and the Cold Fraction (the percentage of the air supply that’s directed to the cold end…the lower the Cold Fraction, the colder the air.)
Anyway, the 15 SCFM Generator is the lowest capacity of the three, producing 1,000 Btu/hr of cooling. The other two are rated for 25 and 30 SCFM (1,700 and 2,000 Btu/hr, respectively.)
He decided to try and replace the 15 SCFM Generator with the 30 SCFM one…his thought was “go big or go home” – and found that he could get twice the flow, with the same temperature drop, as long as he maintained 100psig compressed air pressure at the inlet port. This was more than enough to blow the part & tool clean, while keeping the cutting tool cool, and preventing the plastic part from melting.
If you’d like to find out how to get the most from a Vortex Tube Spot Cooling Product, give me a call.