Keep Small Parts Cool with EXAIR’s Mini Cooler

As they always say, “big things come in small packages”. Oftentimes, some of the things that have the most value or quality are quite small. Jewelry or diamonds certainly come to mind as some high-quality items that are relatively small in size. One little product we have at EXAIR is the Mini Cooler. Don’t let the word “Mini” fool you. EXAIR’s Mini Cooler packs a powerful punch while using minimal compressed air and not taking up valuable space on your shop floor.

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Single and Dual Point Mini Cooler

The Mini Cooler is a proven, reliable way to reduce downtime and increase productivity on a wide variety of operations involving small parts where heat is causing a problem. With just an ordinary supply of compressed air as the power source, the Mini Cooler uses Vortex Tube technology to produce a 20°F (70°F compressed air temp) stream of cold air. This cold air can be directed to the part to prevent heat build-up that can cause premature tool wear, affect part tolerances and improve product finish. The Mini Cooler consumes just 8 SCFM of compressed air when operated at 100 PSIG, making it an ideal solution when available compressed air is at a premium.

The Mini Cooler can be used for a wide variety of applications, many of which we’ve blogged about here before. This application discusses a manufacturer that made surf casting bags used by fishermen fishing straight off of the beach. They had problems with the needle overheating and breaking which in turn damaged the finished product. Not only were they wasting materials, but also time spent periodically replacing the needles on the sewing machines. A focused stream of cold air from the Mini Cooler was all it took to remedy the situation.

Another application that I had the pleasure of seeing while visiting in Hungary was at a manufacturer of cataract lenses. They were using both the Adjustable Spot Cooler and the Mini Cooler in the milling process of the lenses. The cold air from the Mini Cooler replaced expensive and messy liquid coolant and was capable of maintaining a consistent temperature on the lens to prevent warping.

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Mini Cooler used to maintain a low temperature on cataract lenses during inspection.

The Mini Cooler is available with both single and dual cold outlets, depending on the part needing to be cooled. The kit will include the Mini Cooler, a swivel Magnetic Base for precise mounting and positioning, either a Single or Dual Point Hose Kit, and a Manual Drain Filter with a mounting bracket included. If you’re experiencing heat related troubles on a small application, take advantage of EXAIR’s Unconditional 30-Day Guarantee and give the Mini Cooler a try. You’ll be HEATED if you don’t!

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

Adjustable Spot Cooler Provides Needed Cooling In Sunglass Lens Manufacturing

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.

Model 3825 Adjustable Spot Cooler System

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.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

sunglasses image courtesy of passer-by via creative common license.

 

Flat Super Air Nozzles – Quiet and Forceful and Adjustable

The 2″ Flat Super Air Nozzle is a very powerful yet quiet engineered nozzle.  Operation at 80 PSIG of compressed air pressure yields a strong 1.38 lb. of force, at only 77 dBA of sound level.  Compare this with many of the plastic flat nozzles that blow air through a series of holes, with sound levels ranging form 78-83 dBA, not to mention some might violate the OSHA dead ended pressure standard and results in fines being levied.

The patented technology utilizes a changeable shim to generate the high flow of air in a smooth and laminar flow, to keep noise down and power and strength up. With (6) stainless steel shim thicknesses available, the 2″ Flat Super Air Nozzle offers a very flexible package that can be set and tuned to meet exacting performance criteria, while using the minimum amount of compressed air, and at the quietest possible sound levels.

2 Inch Flat
2″ Flat Super Air Nozzle

The model 1122 is offered in a zinc aluminum alloy body and cap, and the 1122SS is constructed from type 316 stainless steel.  All shims are stainless steel. The shim thickness for the 1122/1122SS is 0.015″ thick.

Also available, for extra blowing force, are the HP1125 and HP1125SS.  The nozzles utilize the same zinc aluminum alloy or stainless steel body and cap and have the 0.025″ shim installed – and deliver 2.2 lbs of force, while only increasing sound levels to 83 dBA.

Shim sets for any of the 2″ Flat Super Air Nozzles are available.  The 1132SS shim set includes shims of thickness of 0.005″, 0.10″, and 0.020″.  For higher force levels, the HP1132SS shim set includes the 0.020″ and 0.030″ shims.

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Shims are available, from 0.005″ up to 0.030″ for maximum versatility and performance tuning

As you can see- for a versatile, forceful and quiet engineered air nozzle, it is hard to beat the EXAIR 2″ Flat Super Air Nozzle.  If a 1″ wide nozzle better suits your needs, the same flexibility and power can be found in the 1″ Flat Super Air Nozzle as well.  Check it out as well.

If you would like to talk about Flat Super Air Nozzles or any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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When Efficiency And Practicality Collide

Even if you’re a casual reader of our blogs, you already know that EXAIR Application Engineers LOVE to preach efficiency in the use of compressed air…it’s our “bread and butter;” the very nature of our business. This year, we’re celebrating thirty-five years of leading the way in the development of efficient, safe, and quiet compressed air products. Our track record of success as a solutions provider across a diverse range of industrial and commercial applications is well documented in our blogs, as well as Knowledge Base and Case Study Libraries.  We devote considerable resources (engineering, research & development, product testing, etc.) to making certain that EXAIR Intelligent Compressed Air Products cost less to operate, and perform better, than whatever you’re using right now.

Strange as it may seem, though, sometimes our products are EXTREMELY popular in cases where they INCREASE a facility’s consumption of compressed air…by replacing something that DOESN’T use compressed air at all:

*I’ve written before about how our Large Maximum Cold Temperature Vortex Tubes have replaced liquid nitrogen rigs in freeze sealing operations.  Now, a Vortex Tube directs a portion of its air supply to (usually) unusable hot exhaust, in order to generate the usable flow of cold air.  When compared to the costs of liquid nitrogen and the resources involved to get it where it needs to be, though, the cost of the compressed air needed to operate the Vortex Tube is indeed the practical solution.

A 1/4 ton of refrigeration from a product that fits in the palm of your hand, and all you need is a supply or compressed air!

*Line Vacs are probably THE prime example of the value of using compressed air where it wasn’t used before…replacing a “bucket and ladder” operation:

Straight from our Catalog, a perfect example of using valuable compressed air to save even more valuable resources.

*Then there are the situations that just come down to time.  In large spaces, our Super Blast Safety Air Guns can be used to “sweep” the floor in a fraction of the time it takes an operator with a push broom.

Super Blast Safety Air Gun makes short work of large area cleanup.

To make a long story just a little bit longer…if you’re using compressed air, you can use it better with EXAIR’s engineered compressed air products.  And there are plenty of practical applications where you’re not using compressed air right now too.  If you’d like to find out more about either one, give me a call.

Russ Bowman
Application Engineer
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How Versatile Are EXAIR Compressed Air Products?

I wish I could quantify that, but we keep finding more and more applications for them:

Vortex Tubes are used all the time for cooling applications, down to MINUS 40 degrees (Fahrenheit OR Celsius…that’s the point where they’re both the same; no math required.) They also produce a HOT air flow, which we usually call “exhaust,” but some users actually use IT for heating, and call the COLD flow the “exhaust.”

The EXAIR Vortex Tube. Cold air from one end; hot air from the other. Fully adjustable. You can use either...it's fine with us; whatever you need.
The EXAIR Vortex Tube. Cold air from one end; hot air from the other.  You can use either…it’s fine with us; whatever you need.

Our E-Vac Vacuum Generators are popular for “pick-and-place” jobs…hook one up to a Vacuum Cup and you can move parts around all day long. One time, though, I helped a

customer who needed to “pick-and-place” individual small pieces of woven fabric, a lot like a coffee filter. Even our smallest E-Vac, supplied from a Pressure Regulator cranked all the way down, was too much…it would still pick up most of the stack. We found they could use a Model 120020 3/4″ Super Air Amplifier just fine…the Pressure Regulator was still cranked all the way down, and it picked them up one at a time.

No matter what you need to pick-and-place, we've got you covered.
No matter what you need to pick-and-place, we’ve got you covered.

Our Super Air Knives are perfect for blow off, drying, and cooling applications…whether you’re trying to rid your product of dirt/debris, water, or heat, a laminar curtain of adjustable air flow is a “textbook” solution. But I recently had the pleasure of helping a customer who needed to KEEP SOMETHING IN PLACE and called to ask about an Air Knife. They had small cups running single-file down a conveyor belt, with an overhead brush roller pushing down on them at one point so they could be treated on one side. Without something holding them in place, the tooling would simply push them off the side of the conveyor. It required frequent adjustment because they run different sized cups…and they almost always lost some cups when they switched to a different size, while “dialing in” the brush tension. By installing a Model 110036 36″ Aluminum Super Air Knife in place of the brush, they can hold any size cup in place with the downward air flow “curtain.” No more lost product when they don’t get the brush adjustment just right!

Continuous, even, fully adjustable curtain of air...EXAIR Super Air Knives come in lengths from 3 inches to 9 feet.
Continuous, even, fully adjustable curtain of air…EXAIR Super Air Knives come in lengths from 3 inches to 9 feet, in stock.

If you have a compressed air application you’d like to discuss, give me a call.  Perhaps we’ll find the next level of versatility!

Russ Bowman
Application Engineer
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Real Heroes of Science: Rudolf Hilsch

Rudolf Hilsch helped to advance vortex tube technology into what it is today.

If you look into the history or even the definition of a vortex tube, you’re likely to find mention of a physicist named Rudolf Hilsch.  Born December 18th, 1903, Hilsch was a German physicist, professor, and manager of the Physics Institute of the George August University of Göttingen.  He received a doctorate degree by the age of 24 and spent his career furthering the advancement and understanding of numerous phenomena of physics.

Although Hilsch didn’t invent the Vortex Tube (the original inventor was a physicist by the name of Georges J. Ranque), he is entwined with their history thanks to a paper he published in 1947.  According to lore, this paper significantly changed the understanding and performance capabilities of the vortex tube, eventually being marked as the precursor for identifying a vortex tube as a real potential cooling device. (I’ve made attempts to find this 1947 publication properly translated into English, but to no avail.  If you have it or find it, please email it to me at LeeEvans@EXAIR.com! (Original publication in German can be found here.)

Given that vortex tubes are a known EXAIR solution, it seems reasonable that today, on Hilsch’s birthday, we give recognition to this influential physicist and his mark on thermodynamic fluid flow technology.  And, although we at EXAIR are connected to Hilsch through vortex tubes, everyone alive has been influenced by his work.  This is because Hilsch and a partner (physicist Robert Wichard Pohl) constructed the first semiconductor amplifier in 1938, prompting Hilsch to prove (in 1939) that solid-state electronics are possible.  This work paved the way for transistor and solid-state electronics technology as we know it today.  Without Hilsch and his life’s work, not only would we not have vortex tubes, we likely would have any electronic devices we use every day.

Here’s to you Rudolf Hilsch.  Thank you for your work, your discoveries, and your achievements.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

 

 

Engineered Air Nozzles and Jets Outperform – Save Air, Increase Safety, Save Money

EXAIR’s Engineered Air Nozzles and Air Jets provide a simple solution to lower compressed air usage and reduce noise levels for compressed air blowoff operations.

Why Air Nozzles and Jets – When compared to commonly used open copper tubes or pipes, compressed air savings can be as high as 80%. And with less compressed air, sound levels are greatly reduced.  A 10 dBA noise level reduction is typical.  All EXAIR Air Nozzles and Jets meet the Occupational Safety and Health Administration (OSHA) maximum dead end pressure and sound level exposure requirements. They also carry the CE mark.

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The largest selection of engineered Air Nozzle sizes and materials are only available form EXAIR 

EXAIR Nozzles are engineered to take advantage of the Coanda effect to amplify the airflow up to 25 times or more. Compressed air is ejected through the small orifices and surrounding air is entrained into the main stream. The resulting air stream is a high volume, high velocity blast of air at minimal consumption.  EXAIR manufactures many styles, from the very small, but powerful Atto Super Air Nozzles, to the largest 1-1/4 NPT Super Air Nozzle.  Also offered are 1″ and 2″ wide Flat Super Air Nozzles, and the Back Blow style for cleaning out tubes, pipes, channels or holes from 1/4″ to 16″ in diameter.
EXAIR Air Jets utilize the Coanda effect (wall attachment of a high velocity fluid) to produce air motion in their surroundings.  A small amount of compressed air (1) is throttled through an internal ring nozzle above sonic velocity.  A vacuum is produced, pulling in large volumes of surrounding, or ‘free’ air, through an around the jet (2).  The exit flow is the combination of the two air sources (3).

air-jet
How an Air Jet Works

EXAIR manufactures Air Jets in two types, High Velocity, and Adjustable with materials of construction of brass and Type 303 Stainless Steel.  The High Velocity Air Jet uses a changeable shim to set the gap, controlling the force and flow of the air.  The Adjustable does not use a shim, and has a micrometer gap indicator and locking ring to allow for varying force and flow performance.

AirJetFamily
EXAIR Air Jets – High Velocity type on the left, Adjustable type on the Right

If you have questions about Air Nozzles and Jets, or would like to talk about any EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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