Cold Gun Aircoolant System™: Overview

EXAIR Cold Gun Promotion

Many machining companies like to use coolant to flood their parts for drilling and milling operations.  But what if there was an alternative way?  EXAIR has an interesting technique by using cold air instead of coolant.  This would help save time by eliminating cleaning and drying of parts as well as reducing coolant waste.  EXAIR calls this product our Cold Gun Aircoolant System™.

How the Cold Gun Works

The Cold Gun Aircoolant System uses a Vortex Tube to produce a cold air stream at 50oF (28oC) below supply air temperature.  Heat is one of the major causes for dulling and premature failures for tools, and by blowing cold air, it will reduce the heat buildup in tools while also removing the chips from the surface.  The EXAIR Cold Guns are very compact, portable, and easy to use.  Just attach compressed air to the unit, and it will produce cold air.  Since they do not have any moving parts, Freon, or electricity to operate, it is maintenance-free and long-lasting.  And, EXAIR offers a 5 year “Built To Last” warranty against defects in workmanship and materials.  These systems will extend tool life, improve tolerance control, and increase production rates by replacing coolant during milling, cutting, and drilling operations.

The benefits of using the Cold Gun Aircoolant System extends beyond reducing tool wear, finishing with dry parts, and surface smearing.  It can be used in applications where liquid coolant cannot be used.  This would include wood products, MDF, and plastics.  As insulators, cutting tools will get extremely hot as the material will not remove any heat like with metal chips.  Thus, machining can soften, gall, or burn the surface of the material; allowing only slow speeds for operations.  The cold air from the Cold Gun can keep the tools sharp and the materials hard and firm.  With plastic materials, this is very beneficial as it will keep the plastic rigid for tight tolerance machining.  If burnishing or scoring is occurring, the Cold Gun Aircoolant Systems can help to improve the surface finish of your product.  Other applications would include surface grinders, laser cutters, hot melt setting, and band saws.  The Cold Gun Aircoolant Systems are a low-cost solution that can do a lot of great things to improve processes.

Cold Gun Aircoolant Systems

EXAIR offers two types, the Cold Gun and the High Power Cold Gun.  The High Power Cold Gun blows twice the amount of cold air as the Cold Gun which doubles the cooling capacity.  They come standard with either a Single Point or a Dual Point Hose Kit with a cone and flat nozzle.  All systems come with a magnetic base and a filter separator.  The magnetic base makes this device simple to attach to your machine and start using.  The four models that EXAIR stocks are in the photo above.

EXAIR is running a promotional offer on the Cold Gun Aircoolant Systems.  From now until the end of yr2019; if you buy a Single Point Cold Gun System or a Single Point High Power Cold Gun System; model W5215 and model W5230 respectively, we will include a free model 5902 Dual Point Hose Kit, a $39.00 value, with your system.  And as always, EXAIR offers a 30-day unconditional guarantee for our customers in the U.S. and Canada to try them out.  If you have an application that you believe would be better served with an EXAIR Cold Gun Aircoolant System™, contact an Application Engineer.  And take advantage of our promotional offering by receiving a FREE Dual Point Hose Kit.

 

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

Promos, Freebies, and Some Amazing Products

Like many companies, here at EXAIR we generally always have a promotional offering.  These rotate throughout the months and this month is no different.  The current offering involves the EXAIR Cold Gun Aircoolant Systems.

These systems help to reduce cutting fluid use, increase production speeds, increase tool life, and has helped more customers than I know.  One customer in particular is a maintenance worker from a welded tube manufacturer.  This facility had very little amount of downtime permitted due to the high efficiency and high volume of orders.  When a machine went down the maintenance team were in like a trauma team to determine the cause of failure and get it remedied to get the line back up and running. One of the biggest problems they would have is when they would have to dry machine a quick part to get the machine back up and running, this would either ruin tools or they would have to slow down the machining time to get the surface finish and dimensions they truly needed.  After talking with us the team ordered a Single Point Cold Gun Aircoolant System as these parts were generally smaller shafts or machine dogs.

They received the system in and sure enough a machine went down.  The crew went to work and once the part needed was found they got to work on their lathe trying to make a new piece.  The Cold Gun held itself straight to the headstock thanks to the integrated magnet and the flexible single point hose kit routed the cold air straight to the cutting point.  They didn’t have to fill up the liquid tank or setup the mist system on the lathe, they simply turned on the compressed air and let the lathe do the work.  They were able to take what had recently been around a three hour machine job with heavy wear on tooling to a two hour job, no finish pass was needed on the part, and their tools weren’t completely spent by the end of the job.

They got the part back into the machine, made adjustments, and then went to work getting the machine back into production.

Right now, if you would like to try out a Cold Gun Aircoolant System you can order before 12/31/2019 and use the link to order through our promotion in order to receive a free Dual Point Hose Kit with your qualified purchase.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Cold Guns for Spot Cooling or Replacing Mist Systems

By using only a source of compressed air, the Cold Gun and High Power Cold Gun produces a stream of clean, cold air 50°F (28°C) below your compressed air supply temperature. The Cold Gun is very quiet at only 70 dBA and has no moving parts to wear out. Just supply it with clean compressed air and it’s maintenance free.

How does it work, and what are the benefits?

  • The Cold Gun uses compressed air to produce a stream of clean, cold air at 50°F (28°C) below supply air temperature. Generally this will be 20°F-30°F outlet temperature.
  • They use Vortex Tube technology…no moving parts to wear out.

How A Vortex Tube WorksInstant cold air flow with no moving parts!

  • Cold flow and temperature are preset to optimize cooling capability, and are non-adjustable to prevent freeze-up during use.
  • Eliminates the expense of both the purchase & disposal of cutting fluids when replacing expensive mist systems.
  • Removes the potential for health problems associated with breathing mist & vapors, and the safety issue of slipping on a wet floor.

Cold Gun Aircoolant System selection is easy & straightforward…we offer a standard, and a High Power version to meet your specific needs.

CG
Four systems to choose from, to meet most any need.

We also offer Single & Dual Point Hose Kits, to further meet the needs of your application.

One of the best applications I have seen with our cold gun came from a customer in Peru. They are a gold mining operation and they were having trouble with the liquid they were using to cool a saw. Read all about it here!

IMG_20180613_094120_HDR

If you have an application that you believe would be better served by the use of an EXAIR Cold Gun, give us a call.

Jordan Shouse
Application Engineer
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EXAIR’s Huge Variety of Air Nozzles is Like an Equalizer for your Application

MCS 3035 Final

Many of us are familiar with what an equalizer (EQ) looks like and what it does. Unfortunately, sometimes they get a bad rap from so-called audiophiles, which in my opinion are defined individuals who spent so much money on their equipment they can’t afford to buy any music to play!  Typically, they insist that tone controls must be set to flat because the sound recording engineers mastering the music have already equalized the recording to perfection and if you need to attenuate or cut certain frequencies it is an indicator of poor-quality equipment, and that is simply is not true!

Let’s consider some of the reasons why an equalizer makes sense and, in my opinion, an absolute necessity. The objects and materials in the room will change the sound reproduction characteristics of any speaker system.  If you have large floor standing speakers positioned in the corners of the room, sitting directly on wood floors the speakers are now “acoustically coupled” with the floor and the walls.   On the other hand, if you move the speakers away from the wall and/or place them on spikes or stands (isolating them for the floor) you would have “acoustically de-coupled” the speakers from the walls and floor, which will reduce the bass or low-frequency loudness. This all affects the perceived loudness and/or quality of the music we want to listen too.

This is where the graphic equalizer shines, no need to move the speakers around or use speaker stands or spikes.  An equalizer will allow you to increase or decrease the loudness of multiple frequencies.  You can completely customize your sound to suit your tastes, overcome issues with your listening room acoustics, the speakers you are listening with or even anomalies with the music recording.

Like adjusting an equalizer to suit your room acoustics, speaker size and/or speaker frequency response, EXAIR understands that the need for many different options gives you the necessary adjustments for a successful application.  A few sizes of Air Nozzle, Air Jet or High Force Air Nozzles will not solve every application with the highest efficiency or effectiveness.  EXAIR’s air nozzle variety allows you to produce maximum effectiveness based upon the air pressure and air volume you have available.  Whether you need a strong blast or a gentle breeze, if you have tricky mounting positions or remote applications, EXAIR has the largest selection to choose from and solve your production problem.

We clearly state compressed air volume requirements in SCFM (Standard Cubic Feet per Minute) at a given operating pressure in PSI (Pounds per Square Inch), force at 12” from the compressed air outlet and the sound loudness in dBA at 3′ from the nozzle. These details provide the starting point for selecting the best air nozzle.

When you are looking for expert advice on safe, quiet, efficient, and engineered point of use compressed air products give us a call.   We would enjoy hearing from you!

Steve Harrison
Application Engineer
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The Case for the Cold Gun

Heat is an unavoidable by-product of any cutting or machining operation. Think about it: you’re creating friction on a piece of material with a fast-moving piece of harder material in order to forcibly separate pieces of the original material from its existing shape & size. No matter what, something’s going to get hot: the work piece, the tooling, or (almost always) both. If you don’t do something about it, your parts can become damaged, your tooling can become dull and brittle, and productivity will suffer.

There are ways to alleviate the problem…you can slow the speed of your tooling, but that’s hardly practical, and only marginally effective.  You can use liquid cooling…in fact, you may have to if the particulars of the operation require the lubrication you can only get from a cutting oil or liquid coolant.  But those can be messy, expensive, and the time you spend maintaining the coolant could certainly be spent better elsewhere…like, on machining your products!

The EXAIR Cold Gun Aircoolant System is a novel solution to these problems…heat related and otherwise:

  • The Cold Gun uses compressed air to produce a stream of clean, cold air at 50°F (28°C) below supply air temperature.
  • They use Vortex Tube technology…no moving parts to wear out.
Instant cold air flow with no moving parts!
  • Cold flow and temperature are preset to optimize cooling capability, and are non-adjustable to prevent freeze-up during use.
  • Eliminates the expense of both the purchase & disposal of cutting fluids.
  • Removes the potential for health problems associated with breathing mist & vapors, and the safety issue of slipping on a wet floor.

Cold Gun Aircoolant System selection is easy & straightforward…we offer a standard, and a High Power version to meet your specific needs.

Four systems to choose from, to meet most any need.

We also offer Single & Dual Point Hose Kits, to further meet the needs of your application.  Right now, you don’t have to decide up front…order a Cold Gun Aircoolant System with a Single Point Hose Kit before December 31, 2018, and we’ll throw in the Dual Point Hose Kit for free.

If you’d like to find out more about how Cold Gun Aircoolant Systems can improve your machining or cutting operations, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Going Outside The Box With Vortex Tubes

Among EXAIR’s comprehensive line of Intelligent Compressed Air Products, the Vortex Tube stands out as a unique, and fascinating, solution for a variety of applications requiring a flow of cold air:

  • Cabinet Cooler Systems: clean, cold air to protect electrical and electronic components housed in an enclosure.  Installs in minutes; no moving parts; reliable & maintenance free.
  • Cold Gun Aircoolant Systems:  Direct, focused flow of cold air to replace messy coolant in machining, cutting, drilling, grinding, etc., applications.  Integral magnet base for quick & easy installation; single or dual outlet hose kits; standard or High Power to meet any need.  Optimized flow for maximum cooling and freeze prevention.
  • Adjustable Spot Cooler: Similar to the Cold Guns in many ways, but with variable performance for specific applications.  Cold air to -30°F (-34°C) on demand.
  • Mini Cooler: Similar to the Cold Guns and Adjustable Spot Coolers – magnetic base mounting and single or dual outlet hose kits, but more compact.  Lower flows for smaller jobs.

Then there are the Vortex Tubes themselves…at the heart of all of these products, but perfectly capable all on their own.  In fact, in certain situations, “plain old” Vortex Tubes have been used to do the exact same jobs as all of the above products.  They can even be customized, in and of themselves, to meet specific installation, operation, and/or performance needs:

  • High Temperatures: It should come as no surprise that cold air is often needed because a heat-sensitive item is located in a high heat environment.
    • Vortex Tubes come standard with plastic Generators and Buna o-rings, which are good for ambient temperatures up to 125°F (52°C).
    • High Temperature Vortex Tubes are fitted with brass Generators and Viton o-rings for environments where the temperature can reach 200°F (93°C).
High Temperature Vortex Tubes are suitable for use in environments up to 200F (93C).
  • Preset temperature & flow: Many times, the ability to adjust the performance of a Vortex Tube is a big benefit, but occasionally it’s a liability.
    • I know none of your co-workers are like this (nor are mine) but I’ve heard of people who think they “know better” and are prone to tampering with something that is (or WAS) working just fine, thank you very much.
    • Perhaps you actually DO know better, through experimentation and experience, the optimal performance setting for your application.  Let’s say, for example, you install Vortex Tubes on a line of your products, and a technician has to “dial it in” to a specific Cold Fraction.
    • Any Vortex Tube can be fitted with a drilled orifice (or “Hot Plug”) to replace  the Hot Valve, which presets performance to a specific, non-adjustable value.  If you know the Cold Fraction you need, it’s as easy as that.  If not, it’s as easy as getting a stock Vortex Tube, setting the Cold Fraction where you want it, securing the Hot Valve in position (piece of tape works just fine,) and sending it in.
Preset Vortex Tubes feature a fixed plug, replacing the Hot Valve shown in this picture.

If you’ve got any other specific requirements – special materials, fittings, custom flow/temperature parameters, etc., give me a call; let’s talk.

Russ Bowman
Application Engineer
EXAIR Corporation
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EXAIR’s High Power Cold Gun Keeps Saw Blade Cool in Mining Operation

Our distributor in Peru recently contacted me with an application they were working on with a customer of theirs that deals in the mining industry. They are one of the largest gold mining companies in South America and were looking for a means of keeping their saw blades cool without having to use any type of coolant or water.

In this specific application, they had been using water to maintain the temperature of the blade while cutting. While this did work, it created quite a mess and also resulted in product contamination. The water on the floor presented a slipping hazard and production would have to periodically be halted so that someone could come by and clean the mess off of the floor. So, not only were they creating a contamination issue, but also a safety concern as well as lost production time.

IMG_20180613_094120_HDR
Cold Guns installed

Our distributor introduced them to EXAIR and our line of Cold Gun Spot Cooling Products. By replacing the water cooling with (2) Model 5230 Cold Gun systems, they were able to maintain the temperature of the blade at 24°C (75°F), well within their specifications. This allowed them to completely eliminate the need for water as a cooling method, improving their worker safety as well as increasing production.

Efixo Demo Cold Gun.png1

EXAIR’s Cold Gun utilizes Vortex Tube technology to create two streams of air: one hot and one cold. The hot air is muffled and exhausted, while the cold air is also muffled and ducted to deliver a cold stream of air directly onto the material needing to be cooled. With only a supply of clean, dry compressed air required to operate, installation is quick and easy. Since the Cold Gun has no moving parts to wear out, there’s also no maintenance required so long as the Auto-Drain filter included in the kit is installed upstream of the Cold Gun.

If you’re tired of dealing with messy water-based cooling systems or equally messy coolants, give an Application Engineer a call today and try out a Cold Gun. With our Unconditional 30 Day Guarantee, there’s absolutely no risk to do so!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD