Now through the end of 2017 if you purchase a Single-Point Cold Gun Kit with Model W5215 for the standard Cold Gun or W5230 for the High Power Cold Gun, we’ll include a free Model 5902 Dual Point Hose Kit, a $35.00 value!!
EXAIR’s Cold Gun was a Product of the Year finalist in 2007. By using only a source of compressed air, the Cold Gun and High Power Cold Gun produces a stream of clean, cold air 50° (28°C) below your compressed air supply temperature. The Cold Gun is very quiet at only 70dBA and has no moving parts to wear out. Just supply it with clean, dry compressed air and its maintenance free!
The Cold Gun is pre-set to an 80% Cold Fraction. In other words, 80% of the compressed air supplied to it will exhaust from the cold end of the tube, 20% from the hot end. This prevents the Cold Gun from freezing up during use and optimizes the gun’s cooling capacity. The Cold Gun is an ideal alternative to messy and expensive coolant mist systems. It eliminates the cost of purchase and disposal of cutting fluids as well as worker related health problems from breathing airborne coolant or slipping on wet floors. Replacing a coolant based system also eliminates the need for secondary cleaning operations after milling or drilling.
The Cold Gun is an invaluable tool for machining a wide range of plastics and other materials that may become contaminated when using traditional coolants or oils. The clean, cold air from the outlet of the Cold Gun keeps the part cool, clean, and dry. Take for example this application where an OEM for the plastics industry uses EXAIR Cold Guns in place of a coolant system.
If you have an application that you believe would be better served by the use of an EXAIR Cold Gun, give us a call. Get one on order today and take advantage of receiving a FREE Dual Point Hose Kit!
During a recent visit with our Hungarian Distributor, I had the opportunity to take a look at an application using some EXAIR Adjustable Spot Coolers and Mini Coolers. The company manufactures cataract lenses and is using the coolers in a dry machining application. The previous process involved using a liquid coolant which caused a washing operation to remove the contaminants before the lenses could move on to the next step of the process. This was not only time consuming, but the solution they needed to use as a coolant was very expensive due to strict regulations that they had to adhere to.
The lenses are set up on a lathe which are precisely cut. The Adjustable Spot Coolers were positioned with the cold airflow just at the point of cutting to keep the temperature at a specific point. If the lenses get too hot, the material becomes less rigid and begins to warp. When this happens, the lens cannot be reworked and must be scrapped. Immediately after coming off of the lathe, an inspector places the lens under a microscope for inspection. At this point, a Mini Cooler is installed to ensure that the temperature of the lens stays cold. If the lens passes inspection, it is immediately placed in a small freezer next to the operator. Temperature probes are in place at several points during the process to ensure that they do not go above the specified temperature.
By implementing a solution with the Adjustable Spot Cooler, this customer was able to boost productivity by removing a cleaning step from the process and also reduce costs by eliminating the need for the costly coolant solution that was required. If you’d like to replace messy coolant systems in your machining operation with a clean compressed air solution, give us a call. An Application Engineer will be happy to look at your process and recommend the most suitable solution.
Machining plastics can be a difficult task as the contact between the part and the tool generates heat, which can result in the plastics beginning to melt and stick to the tooling, causing deformities or even broken tool heads. Often times, companies will introduce a liquid based method of cooling to quench the parts during machining, while this does work, with plastics they tend to absorb some of the liquid, resulting in the finished part being outside the allowable tolerance range. Another area of concern is the mess that liquid cooling creates as now the parts need to be dried and cleaned before they can continue to the next process.
Such was the case last week when I worked with an OEM who was looking for a way to cool the tooling in the machines they build for the plastics industry. The company they were selling the machines to, specifically asked for an alternative method of cooling without using any type of coolant due to the conditions mentioned above. Once again, EXAIR has the perfect solution – the Cold Gun. Incorporating a Vortex Tube, the Cold Gun produces a cold air stream at 50°F below compressed air supply temperature and provides 1,000 Btu/hr. of cooling capacity. Fitted with a magnetic base and flexible hose the unit can be mounted virtually anywhere on the machine and the cold airflow can be easily directed to provide cooling to the critical area. The system also includes a filter separator for the supply line to remove any water or contaminants, ensuring that the exiting airflow is clean and free of debris.
When looking for a reliable method of cooling, whether machining plastics or other material, the cold, clean air from the Cold Gun is the ideal solution in place of messy misting systems. For help with your spot cooling needs or to discuss how using Vortex Tube technology could help in your process, give me a call, I’d be happy to help.
If you’re looking at replacing messy coolant mist systems, look no further than the Adjustable Spot Cooler. EXAIR’s Adjustable Spot Cooler incorporates Vortex Tube technology to produce temperatures ranging from -30°F – +70°F. A Vortex Tube works by imparting a rapid spinning motion to the supplied compressed air. This airflow makes its way to the end of the tube where it is forced to abruptly change directions. It is during this change of direction that energy is given off in the form of heat. The hot air then exits the tube from the hot end, while cold air exits the other end of the tube. As the valve is opened to allow more air to exhaust from the hot end, the temperature at the cold end will decrease. At a sound level of just 73 dBA when operated at 100 psig and stock generator installed, this compact cooler will keep your operation cool, clean and dry without causing unnecessarily high noise levels.
When looking at a Vortex Tube based solution, the variety of options can sometimes be daunting. This is where the versatility of the Adjustable Spot Cooler shines. Through a simple turn of the control knob, you can easily adjust the temperature and cold fraction of the unit. Additionally, the kits come with (2) extra generators (15-H and 30-H) that can be swapped out for the stock generator for more/less cooling power and air consumption. The 15-H generator will deliver up to 1,000 Btu/hr of cooling capacity and the 30-H will provide up to 2,000 Btu/hr of cooling capacity. We have (2) different kits available, the Model 3825 Single Point and the Model 3925 Dual Point Kit. The 3825 is recommended for use in applications where you’re cooling a small surface such as solder joints, hot melts, or drilled plastics. The 3925 system is better served when heat is generated over a larger surface area such as saw blade cooling. The kits use flexible Loc-Line hose to allow you to precisely position the cold airflow onto your target. The Adjustable Spot Cooler provides easy mounting with a swivel magnetic base, allowing you to mount the cooler directly at the most critical point that heat is being generated.
If you’re tired of cleaning up your coolant or have an application that requires dry machining, get one of the Adjustable Spot Cooler systems on order today. They’re in stock ready to ship!
When working with a cooling application, many customers will immediately look to the Vortex Tube and Cold Gun product lines. While this may be the best solution for some applications with smaller areas to cool, cold air from a Vortex tube based solution is not the best method for large parts or larger areas that exceed a footprint of approximately 2″ x 2″. For larger areas, we have other options for many cooling applications. EXAIR’sSuper Air Amplifiers and Super Air Knives are also very effective at reducing the temperature of a part without requiring cold air.
Cooling is a relative concept based on the starting and finishing temperature. What feels “cool” to a human being does not necessarily mean the same thing as “cooling” a part or material. Due to the ability of the Super Air Knives and Super Air Amplifiers to entrain large amounts of ambient temperature air, we can move a lot of air volume across the surface of the target part and quickly lower the temperature.
A simple example I like to use is blowing on a hot cup of coffee just as its been brewed. The temperature of the air coming from your mouth is around 98.6°F, the same as your body temperature. Coffee can be as hot as 185°F when fresh. Due to the temperature differential between your breath and the hot coffee, we’re able to achieve a reasonable amount of cooling just by simply blowing across the surface. Typically, when the target temperature of the part or material needs to be around ambient temperature or higher; the best solution for cooling is going to be either a Super Air Amplifier or Super Air Knife.
To illustrate the above concept even more, recently I was working with a customer that needed to cool a silicon injection mold. The mold had two sides and the customer was looking for a method of cooling it down between cycles. The mold cavity surface was approximately 400°F and they wanted to get it down to around 150°F. They were familiar with the EXAIR Cold Gun as they use them across their facility in various secondary or post-molding drilling operations. They had a spare and decided to hook it up and blow the cold air across the face of the mold to see what happens. The volume of air from the Cold Gun was not enough to sufficiently cool the entire mold, so he reached out to EXAIR for assistance.
Based on the dimensions of the mold and understanding the target temperature to be 150°F, we settled on a system of (2) 120224 4” Super Air Amplifier Kits. One was placed above each side of the mold. As soon as the mold opened, they activated the Super Air Amplifiers and were able to pull the surface temperature of the mold down to an acceptable level. Time is money in any manufacturing operation. Companies that produce injection molded parts will look for any way to improve their process. By implementing a procedure to cool the mold more quickly, they are able to boost their productivity gains and become more profitable.
The Super Air Amplifier Kit comes with an Auto-Drain Filter to keep the air clean and dry, a pressure regulator to allow you to dial in the precise level of airflow, and a shim set that allows you to make gross adjustments to the flow. The Super Air Amplifier is available in (5) different sizes with ¾” up to 8” diameter outlets and flow rates from 219 SCFM to 9,000 SCFM 6″ from the outlet. They are capable of achieving an amplification ratio of up to 25:1 from the compressed air supply. The laminar airflow from the unit minimizes wind shear to produce sound levels that are typically three times quieter than other air movers. If you have an application that requires a similar type of cooling, give us a call. We’ll walk you through the process of selecting the most suitable solution.
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.
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.
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.
When it comes to die stamping, friction generates heat. Heat can be a big cause in slowing production and decreasing tool life.
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.
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.
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.