Tag: Cold Gun

Discover the EXAIR Mini Cooler

Published on by Jordan T ShouseLeave a comment

In the fast-paced world of manufacturing, cycle time is a key factor in profitability. With most industrial operations, as you speed up equipment, heat becomes a big factor. Whether it’s a high-speed sewing machine scorching delicate fabrics or a lens grinder building up friction on optical components, uncontrolled heat leads to defects, downtime, and frustrated operators.

Enter the EXAIR Mini Cooler—a compact, no-moving-parts cooler that delivers instant cold air to keep your small-scale operations running smoothly. If you’re tired of heat-related headaches, this device might just be your next workshop hero. What is the EXAIR Mini Cooler? The EXAIR Mini Cooler is a vortex tube-based spot cooling system designed specifically for small parts and high-speed processes where traditional cooling methods fall short. Powered solely by compressed air, it generates a focused stream of cold air at an impressive 20°F (-7°C), effectively preventing heat buildup without the need for refrigerants, electricity, or complex setups.

At its core, the Mini Cooler is engineered for portability and ease of use. Available in two primary configurations:

Each system comes complete with a swivel magnetic base for quick mounting, a manual drain filter separator to ensure clean air supply, and flexible hose kits tailored to the application. No tools required for installation—it’s ready to go out of the box.

How Does It Work? The Magic of Vortex Technology The secret sauce behind the Mini Cooler’s chill factor is EXAIR’s vortex tube technology, a simple yet ingenious principle that’s been refined over decades.

Here’s the breakdown:

  1. Compressed Air Input: Ordinary shop air (typically 80–100 psig) enters the unit.
  2. Vortex Creation: Inside the tube, the air is forced into a high-speed vortex, splitting into two streams moving in opposite directions.
  3. Heat Separation: The outer stream heats up, while the inner one cools dramatically through energy transfer—resulting in cold air exiting one end (at 20°F) and hot air from the other (which can be easily vented away).
  4. Focused Delivery: The cold stream is directed precisely via adjustable hoses and nozzles, right where you need it.

This process happens instantaneously with zero moving parts, making it maintenance-free and incredibly reliable. Unlike electric coolers that can fail under dust or vibration, the Mini Cooler thrives in harsh industrial environments.

Plus, it’s adjustable: tweak the air pressure or generator for even colder temps down to -50°F (-46°C) if your application demands it.

If you’re not sure which Cooling Product fits your needs, EXAIR Application Engineers are standing by to help specify the right one for you…give me a call.

Jordan Shouse, CCASS

Application Engineer

Send me an email
Find us on the Web 

Theory of a Dead Man

Published on by jasonkirbyLeave a comment

Georges-Joseph Ranque was born on February 7, 1898, in Ambérieu-en-Bugey, France, to Léon-Joseph Ranque, a railroad engineer. This familial background naturally fostered his passion for physics. He attended the esteemed Lycée Saint-Louis, a selective post-secondary institution, where he furthered his understanding of the subject. Subsequently, he gained admission to École Polytechnique, continuing his academic journey. During his work on an industrial pump, Ranque became intrigued by the Pantone carburetor and discovered what is now referred to as the Ranque effect. This phenomenon serves as the foundational principle behind industrial vortex tubes, where the tangential injection of compressed gas at high velocity results in the creation of two distinct streams: one hot and one cold.

The unique physical phenomenon of the Vortex Tube principle generates cold air instantly, and for as long – or short – a time as needed.

This cold airflow is effectively employed in various industrial applications for spot cooling and enclosure cooling, thanks to its straightforward and dependable nature. The only requirement is a source of compressed air. In 1931, Georges patented his vortex tube, but it did not gain much traction until physicist Rudolf Hilsch revisited the concept. Hilsch enhanced the design, which he referred to as the “Wirbelrohr,” or “whirl pipe” in English. Consequently, the term “Ranque-Hilsch tube” is often used interchangeably with “vortex tube” due to Hilsch’s contributions.

Compressed air enters the tube and flows through a series of nozzles positioned tangentially to the internal counter bore. This nozzle configuration induces the air to rotate in a vortex at speeds reaching up to 1,000,000 RPM. As the air spins, it makes a 90° turn, where a valve at one end permits a portion of the heated air to escape. The remaining air continues down the tube in the inner stream, losing heat before exiting as cold air at the opposite end.

How a Vortex Tube Works

Both streams in a vortex tube rotate in the same direction and at an identical angular velocity. According to the principle of conservation of angular momentum, the rotational speed of the inner vortex is expected to increase. This phenomenon can be effectively illustrated through Olympic figure skating: when a skater extends her arms, her spinning slows down, but as she pulls them in, her rotational speed increases significantly. In the case of a vortex tube, however, the inner vortex maintains a constant speed as it has lost angular momentum. The energy dissipated during this process is released as heat from the hot side of the tube. This heat loss facilitates the cooling of the inner vortex, enabling it to be harnessed for various industrial applications.

The theory behind Vortex Tubes is applied in standard Vortex Tubes as well as in a range of other products designed with specific features tailored to various applications. EXAIR offers a selection that includes Cabinet Coolers, Cold Guns, Adjustable Spot Coolers, Mini Coolers, and Vortex Tubes, all of which function based on this fundamental principle.

 If you have any questions about Vortex Tubes, or anything regarding EXAIR and our products, please do not hesitate to reach out. We would love to hear from you!

Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk

Mini Cooler Overview

Published on by jasonkirbyLeave a comment

The basic vortex tube has been utilized in numerous industrial cooling applications over the years. Some of these applications have gained such popularity that they have led to the creation of specialized “applied products” tailored to meet specific needs. These products encompass the Adjustable Spot Cooler, Mini Cooler, Cold Gun, and Cabinet Coolers, all of which are available in our catalog and on our website.

The Mini Cooler utilizes a vortex tube to transform a limited quantity of compressed air into two low-pressure streams that flow in opposite directions, one within the other. This interaction allows the two air streams to exchange heat, resulting in the generation of cold air at one end of the tube and hot air at the other. A flexible hose channels the cold airstream towards the surface intended for cooling.

Heat produced by processes like machining, welding, soldering, brazing, electrical losses, and the functioning of rotating or reciprocating machinery poses considerable challenges that extend beyond simple comfort. Efficient heat removal from these activities is crucial for uninterrupted operation, as significant amounts of heat often require dissipation. For example, power plants generating electricity employ large pumps to circulate thousands of gallons of water each minute through extensive heat exchangers, which condense steam from turbines, enabling reheating and sustaining turbine functionality.

The Mini Cooler operates on the Vortex Tube principle to produce cold air from compressed air without any moving components, providing immediate cooling on demand. This method relies on a physical phenomenon rather than direct heat transfer, allowing the Mini Cooler to deliver cold air at specified flow rates and temperatures as soon as compressed air is supplied. It can be activated or deactivated as frequently as required, and its design eliminates the risk of wear from moving parts or failure of electrical components. With a compressed air requirement of just 8 SCFM at 100 psig, even relatively small compressors, some as low as 3HP, can sustain continuous operation of the Mini Cooler.

If you would like to discuss the Mini Cooler, please do not hesitate to contact an Application Engineer. We are always happy to help!

Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk

Cold Gun Aircoolant Systems™ Versus Messy Coolant

Published on by John BallLeave a comment

In any machining operation, tool wear is unavoidable.  Cutting tools heat up due to friction, and this heat contributes to premature tool wear.  As tooling wears, poor tolerances and dimensional inaccuracy are common.  Additionally, as the cutting edge dulls, increased cutting force is required, which further increases the amount of heat generated. 

Coolants are used to reduce friction and help mitigate some of the wear by reducing heat, but then you’re left with a mess on the part and in the machine itself.   The fine mist will create a fog which will stick to the wall and personnel.  Also, with the dirty parts, cleaning will take additional manpower and time.  What if I were to tell you that there’s a way to safely, effectively, and easily perform machining, grinding, and cutting operations without coolant?  I would like to introduce you to EXAIR’s Cold Gun Aircoolant System™. 

The Cold Gun utilizes the vortex principle to produce a cold air stream that will provide chip evacuation and cooling at the cutting tool and material. The vortex phenomenon will drop the incoming compressed air temperature by 50°F (28oC).  So, if you supply compressed air at 70oF (21oC), it will blow cold air at a temperature of 20oF (-7oC).  This means that the removal of chips by using cold air will help reduce the heat buildup within both the cutting tool and the material, which can help prevent thermal creep. Keeping the cutting tool and the material cooler reduces the amount of wear on the tooling and or coating of the tool and has been found to reduce tool wear by over 21%.

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 a great system for machining a wide range of materials like plastics and MDF, or for grinding 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.  

If you have an application that you believe would be well-served from the cold airflow generated by an EXAIR Cold Gun, an Application Engineer will be happy to assist you.  We offer a Cold Gun and a High Power Cold Gun which reduces heat even faster.  Get one on order today and take advantage of our limited time promotion and receive a FREE Dual Point Hose Kit upgrade for qualified online purchases. 

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb