Tag: coolant

A Referral for the Chip Trapper: Made by EXAIR, and Used by EXAIR.

Published on by johnball2014Leave a comment

Being that EXAIR is a manufacturing plant, we also have CNC equipment that utilizes coolant to reduce tool wear.  The downtime for cleaning and replacing the coolant was too long.  To speed things up, as time is money, EXAIR created a system to clean the coolant and replace it back into the sump.  I want to share the features and benefits that we see in using our EXAIR Chip Trapper. 

One of the biggest issues with coolants is the breakdown of the fluid.  This can be caused by bacterial growth, tramp oils, and a lack of filtration.  Since we began using our Chip Trapper System in our machining area, we’ve seen some great improvements.  I spoke with our lead machinist, and he gave me the following points: 

  • The complete coolant change-out went from every 4 months to once a year. 
  • Reduced the number of barrels of coolant concentrate from 10 barrels to 4 barrels per year.  Roughly $5,000 in annual savings
  • Bacterial growth is dramatically reduced as the Chip Trapper aerates the coolant.
  • Filter bags will remove the chip fines and tramp oils, keeping the coolant fresh. 
  • The time to get the CNC machines back to operational status and making parts went from 2 hours to ½ hour.

CNC machines now come with spindle coolant features.  This new technology helps with the need to increase speeds and feed rates.  The coolant is pumped to the top of the machine and fed directly through the spindle.  This type of spindle uses a rotary union, which keeps the coolant in the spindle while spinning at a high rate of speed.  The rotary union is very expensive and costly to replace.  They are very susceptible to dirty coolant.  If a seal within the rotary union begins to leak inside the machine, you will not be able to diagnose the problem until the machine fails.  The Chip Trapper will help reduce this chance and keep your machine from incurring extreme expenses.

Chip Trapper Cut Away

The unique feature of the Chip Trapper is the vacuum pump.  The vacuum units do not have any moving parts, so they are maintenance-free, quiet, and long-lasting.  Without electric motors, the operator will be safe from electrical shock.  They only require compressed air to operate.  We offer two types: the Chip Trapper System and the High Lift Chip Trapper System.  The Chip Trapper System is a great tool for coolant sumps on the floor level.  The High Lift Chip Trapper System has a bit more power to draw in liquid from sumps below floor level and for fluids with higher viscosity.

EXAIR has three different volumes to select.  We have 30 gallon (113 L), 55 gallon (208 L), and 110 gallon (416 L) drums.  The system comes complete with a drum dolly, a 20 foot compressed air line, a shut-off valve, a chip wand, two 5 micron washable filter bags, and a vacuum hose.  The filter bags can be replaced with ones of a different micron to increase efficiency or filter life.  We have 1-micron, 25-micron, 100-micron, and 200-micron filter bags.  If you are not sure which would work best for your coolant, EXAIR does offer a sample pack that will include one of each micron rating, model 901060-SP.  And if it gets really messy in the machine shop, you can add a Spill Recovery Kit to clean up the liquid off the floor.

If you would like to know more about the EXAIR Chip Trapper System, an Application Engineer will be happy to help you.  You can take advantage of the features and benefits that the Chip Trapper provides: ease of use, extended coolant life, no electric motors to fail, and quick change-over.

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

Strut Manufacturer uses EXAIR Back Blow Nozzles to clear ID

Published on by Jordan T ShouseLeave a comment

A few weeks ago I got a call from a large North American manufacturer of Strut Columns. They recently got a large recall on products they were shipping because metal chips and debris were causing the oil seals to wear and leak prematurely. They found that the manufacturing process could leave chips clinging to the inside diameter (ID) of the outer tube and would make it past there visual inspection. They wanted an option to design into a robotic “cleaning station” where the ID would get cleaned while the outside features were getting cleaned as well. Well for me it was pretty easy to select the EXAIR Back Blow Nozzles!

EXAIR Back Blow Nozzle

We offer three different sizes to fit inside a wide variety of diameters from ¼” (6.3mm) to 16” (406mm) ID.  They are designed to clean tubing, pipes, hoses, channels, and extruded “odd” shapes.  The 360o rear airflow pattern can “wipe” without touching the internal surface to remove coolant and chips.  For the application above, I recommended the model 1006SS Back Blow Air Nozzle to fit inside the 2″ (51mm) opening.  The range for this Back Blow Air Nozzle is from 7/8” (22mm) to 4” (102mm) inside diameters.  This 316SS robust nozzle would last a long time without having to change or replace.

Airflow Patterns for EXAIR Back Blow Nozzles

At first they purchased a hand held system on one of our Heavy Duty Safety air guns, This gave them the ability to test the concept out and they found it worked great wiping the ID clean of all unwanted debris. They used the 1306SS-12-CS, this gun with the 12″ extension and chip guard gave them a great platform to test!

Model 1306SS-24-CS Heavy Duty Back Blow Safety Air Gun with Model 1006SS Back Blow Air Nozzle, 24″ Alum. Ext Pipe & Chip Shield

Once they wrapped their testing up, they replaced this manual operation with just the nozzle on a 1.5″ schedule 40 pipe. The nozzle was mounted on the end and a robot would slide the part ID over the nozzle!

This $117.00 nozzle was able to fix an issue that caused hundreds if thousands of dollars in recalls! That’s why we take time and intelligently design our nozzles, the 1006SS was designed for these type of applications and it excels in them!

Using Engineered nozzles can make a big difference in the function of your processes – not only to your financial bottom line, but to everyone’s safety, health, and livelihood.  If you’d like to find out more about how EXAIR can help, give me a call.

Jordan Shouse
Application Engineer

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Twitter: @EXAIR_JS

Back Blow Air Nozzles Clean Inside Aluminum Extrusions

Published on by johnball2014Leave a comment

A manufacturing plant was using extruded aluminum structural framing for making benches.  After the aluminum parts were cut, they had coolant and chips inside the tube.  They tried to run a rag through the center to remove the material, but it wasn’t able to get into all the crevices and before long the rag was saturated.  Also, they noticed that the chips would scratch the internal surfaces.  For this company, quality was very important to represent their brand.  So, they were needing a non-contact way to clean the inside of these parts after sawing.   They contacted EXAIR as we share the same business facets of first-class customer service and great quality.

Back Blow Air Nozzle Family

At EXAIR, we design and manufacture nozzles for just this type of operation; the Back Blow Air Nozzles.  We offer three different sizes to fit inside a wide variety of diameters from ¼” (6.3mm) to 16” (406mm).  They are designed to clean tubing, pipes, hoses, channels, and extruded “odd” shapes.  The 360o rear airflow pattern can “wipe” without touching the internal surface to remove coolant and chips.  For the application above, I recommended the model 1006SS Back Blow Air Nozzle to fit inside the 1 ½” (38mm) opening.  The range for this Back Blow Air Nozzle is from 7/8” (22mm) to 4” (102mm) diameters.  This 316SS robust nozzle would last a long time without having to change or replace cloth rags.

After installing the model 1006SS onto an extension pipe, the cleaning operation became very easy and efficient.  After each cut, they would run the Back Blow Nozzle through the center with only one pass to clean.  The non-contact wiping removed the coolant and chips without marring the internal surface.  In addition, they were able to speed up their operation by 20%.  Cleaner tubes, less time, cost savings; they were happy that they contacted EXAIR for our expertise.

Model 1204SS-6-CS and 1206SS-6-CS

If you need to clean the inside of tubes, hoses, pipes, etc., EXAIR has the perfect nozzle for you, the Back Blow Air Nozzles.  EXAIR can also offer these nozzles on our VariBlast, Soft Grip, and Heavy Duty Air Guns for manual operations.  They come with Chip Shields and extensions that can reach as far as 72” (1829mm).  Or like the customer above, automate the system to get a great non-contact cleaning.  If you require any more details, you can contact an Application Engineer at EXAIR.  We will be happy to help you.

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

The EXAIR Chip Trapper™ System Extends Machine Coolant Life

Published on by johnball2014Leave a comment

Have you realized that you spend too much time cleaning out your CNC machine?  Do you find that It is messy and backbreaking work?  Do you spend too much money replacing the coolant in your system?  If you answer yes to any of these, EXAIR has a product for you; the Chip Trapper System.

EXAIR created this product to reduce the down time and extend the life of your coolant.  This device will save you money and time with productivity, coolant, and repairs.  In this blog, I will go over some of the features and benefits with the Chip Trapper Systems.

EXAIR offers two types, the Chip Trapper and the High Lift Chip Trapper.  They are designed to move fluid into the drum to be filtered, and to allow the clean fluid to be placed back into the sump.  The Chip Trapper works great for quick coolant cleaning at the floor level.  The High Lift Chip Trapper is ideal for cleaning viscous fluids as well as for reservoirs below the floor level.

Both types use a pneumatic two-way pump to move the fluid.  They come in three different drum sizes, 30 Gallon (114L), 55 Gallon (208L), and 110 Gallon (418L). So, you can clean large sump tanks with only one cycle through the cleaning system.  They come standard with a 5-micron bag filter that can hold over 5 gallons of material.

EXAIR can also offer filter bags in 5 other micron ranges from 1 micron up to 200 micron.  And if you are not sure on the other filtration ranges, EXAIR offers a filter sample pack, model 901060-SP, that includes one of each type.

Chip Trapper Cut Away

The Chip Trapper System includes the drum, the two-way pneumatic pump, a drum dolly, a directional flow valve, 10 feet (3m) of vacuum hose, 20 feet (6m) of compressed air hose, a chip wand, a shut off valve, and two additional filter bags.  All you need to do is to attach the Chip Trapper System to a filtered compressed air source.

The High Lift Chip Trapper offers a more powerful pneumatic pump which can fill a 55 gallon (208L) drum in 85 second from 15 feet (4.5m) below.  And, instead of the 10 feet (3m) vacuum hose, it will come with a  20 feet (6m) vacuum hose.

The unique features with the Chip trappers are the abilities to clean the CNC sump very quickly and with less mess.  Also, by using compressed air to pump the coolant in and out of the drum, it will aerate the coolant.  This will reduce bacteria growth and extend the life of the coolant. Thus, saving you money with those more expensive coolants.

Another benefit is that the pneumatic pump does not have any moving parts to wear out.  So, it will last you a long time without worrying about motor failures or loud noises.

You can watch the video of the operation here:

A list of some benefits that you will see if you purchase the Chip Trapper System is as follows:

  • The number of complete coolant change-outs are reduced.
  • The speed to get the CNC machines back operational to make parts.
  • Reduce the number of barrels of coolant concentrate per year.
  • Bacterial growth dramatically reduced as the Chip Trapper aerates the coolant.
  • Filter bags will remove the chip fines and some tramp oils keeping the coolant fresh.
  • Quiet and long lasting
  • A complete system that is easy to use.

As an added note, some CNC machines come with a spindle coolant feature.  This new technology helps in the need to increase speeds and feed rates.  The coolant is pumped to the top of the machine and fed directly through the spindle.  This type of spindle uses a rotary union which allows the coolant to the spindle as it spins at a high rate of speed.  The rotary unions are very expensive and costly to replace.

These spindles are very susceptible to dirty coolant.  If a seal within the rotary union begins to leak inside the machine, you will not be able to diagnose the problem until they have a machine failure.  The Chip Trapper with help eliminate this chance and keep your machine from an extreme expensive breakdown.

When your machine is not operating, your productivity is lost.  The EXAIR Chip Trapper Systems can be that product for you to get you back up and running is a short period of time, extend your coolant life, and keep the area clean and safe.  A win-win proposition in saving money and time.

For U.S. and Canadian customers, EXAIR offers a 30-day unconditional guarantee to try.  And, for a limited time.  an end-user will get a free EXAIR Vac-u-Gun, a $112.00 value, with any purchase of a Chip Trapper or High Lift Chip Trapper.

If you want to learn more about the EXAIR Industrial Housekeeping Products, you can contact an Application Engineer.  We will be happy to help you.

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