Mini Cooler Cools Hot Glue Beads

A few weeks ago I worked with a nail and staple gun manufacturer on a glue cooling process involving their collated nail strips. To keep the nails together, they place a small amount of hot glue across the body of the nails and then have an open air line blowing compressed air on the glue to secure a good bond between the pieces. The current process used to work great, but they recently made a change to the type of glue they were using and now they are starting to see more rejects as the heat from the glue isn’t able to be removed quick enough with ambient air. The customer is familiar with EXAIR as they currently use some of our other products in various applications throughout their plant but in this particular case, they were unsure of the best product to fit their needs so they reached out for assistance.

nails

Example of collated nail strip

For this particular application, I suggested the customer use our Mini Cooler. The Mini Cooler is specifically designed for small area or small part cooling applications. The Mini Cooler uses less compressed air than our Cold Gun but still produces the same 50°F temperature drop from the incoming supply air temperature. So say your plant air is 70°F, you would see 20°F air being exhausted from the unit. The device features a flexible hose, allowing the user to focus the cold air to the desired location, in this case right at the glue which would provide the quicker, more reliable solution the customer was needing. Installation is a breeze as well, thanks to the included magnetic base, you don’t need to make any expensive modifications or add any type of mounting brackets to the existing setup.

3808

The Mini Cooler is the ideal choice for small part cooling.

EXAIR offers a wide variety of spot cooling products that provide a low cost, maintenance free solution for large or small scale cooling processes. With help selecting the best product to fit your specific need or to discuss your particular application, please contact an application engineer for assistance.

Best Regards,
Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

Nails image courtesy of Joy Kirr via Creative Commons license

 

EXAIR Cold Gun Provides Dry Cooling for Gang Drill

gang-drill-1

A gang drill in need of dry cooling

When working with machining centers of any sort, proper cooling is critical to producing in-spec parts.  Inadequate cooling deteriorates the tooling and can lead to defective or rejected parts, so most of us try to avoid overheating whenever possible.  Traditionally, the best way to cool the cutting blade or bit of a machining center was to use liquid coolant, routing the liquid to the required areas of the machine, and then reclaiming the coolant to be used again while cleaning the finished parts of the coolant residue.

This process, while effective, creates a considerable amount of cleanup, both for the machining area, and for the machined parts.  Because of this, dry cooling can provide distinct advantages when compared to a traditional setup.

gang-drill-with-red-arrow

Liquid cooling spilled onto the floor as a result of machining operations

In the setup shown above, a gang drill with 24 drill heads cuts into various aluminum profiles.  As shown in the picture, the process generates a significant strings and chips, and the current setup using liquid cooling results in coolant outside of the desired workspace (see the red arrow in the bottom right, highlighting liquid coolant on the floor – a potential safety hazard).  The end user in this case was in search of a way to maintain cooling for the drills while eliminating the liquid spillover.  The solution, was the EXAIR Cold Gun model 5315 with two cold outlets

When faced with the potential to outfit a machine with a completely new cooling system, we’ve found that a short test can go a long way toward implementing a proper solution.  So, testing a single Cold Gun with two outlets can be tested on a single drill head, with the results reviewed before installing additional units onto the machine.  Our Application Engineering team is available to assist this customer every step of the way with product selection, installation and testing results, and full machine outfitting.

Providing a viable solution and service to the customer have opened the door to removing liquid cooling from this machine.  This will eliminate cleaning of the aluminum profiles after machining, thus reducing the total input required to produce a finished product, and it will eliminate the safety hazard of having liquid coolant on the floor surrounding the machine as well.

If you have a similar application or would like to speak to an Application Engineer about dry cooling, give us a call – we’ll be happy to help.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Adjustable Spot Cooler Keeps Band Saw Blade Cool

flir image

Heat camera image of band saw blade heat

We run into interesting applications that require cooling all the time. Here’s an example of a spot cooling application for a tire cutting application that used a FLIR camera to show the heat generated within the band saw blade.

The customer is a world supplier of tires for various vehicles from ATV to construction use. And they have a need to cut tires up for quality control testing as well as R&D purposes. They were looking for a low cost and efficient way to cool the blade without using liquid coolant or water as those methods require implementation of waste handling schemes that this customer did not want to deal with. So, they came to EXAIR as they knew we specialized in cold air cooling products. Specifically, they had interest in model 3925 (Dual Point, Adjustable Spot Cooler System). The dual point hose kit would allow for even cooling on both sides of the band saw blade. After discussing their application details, we agreed that model 3925 would be the best offering we could make to the customer. As we have a band saw in our workshop, I located some rubber material that we had with similar properties to a tire and made some quick tests to determine that in fact, model 3925 allowed for only a modest 5°C rise in temperature. The customer was quite satisfied at our test result and purchased 4 units for their band saws.

Neal Raker, International Sales Manager
nealraker@exair.com

@EXAIR_NR

 

Cooling Copper Welds with an Adjustable Spot Cooler

In the video above, two strands of braided copper wire are welded together in an automated process.  As the wire travels through the machine, it is heated to 600-800°C (~1100-1500°F) to fuse together, cooled, then cut into strips.  The original setup (shown in the video), was to use water to cool the copper after welding, but this proved to be undesired because residual water was left in the copper braid, leading to quality control problems.  But without proper cooling, the heat created during welding would stress the copper and reduce the quality of the product.

In an effort to remove the liquid cooling from the application, the customer was considering whether a Vortex Tube solution would be able to remove enough heat from the copper in the required timeframe of 10-15 seconds.  The end goal was to maintain the production level of the process, but to remove liquid from the application, and cool the welded copper to 200°C (~400°F).  In order to allow for on-the-fly adjustment, an Adjustable Spot Cooler was chosen for testing purposes.

20160907_081646

This setup surrounded the welded copper with freezing cold air

To configure this setup, the cold outlet of the Adjustable Spot Cooler was fed into a tube surrounding the copper braids (shown above).  This tube surrounded the welded copper with below freezing air to remove the heat and cool the copper.

before-and-after

Results of installing the Adjustable Spot Cooler

The results of this setup are shown above.  On the left is the output of the process without cooling from the Adjustable Spot Cooler (copper of this quality fails quality control checks), and on the right is the output from the same process, but with cooling from the Adjustable Spot Cooler.  The copper on the right is welded, cooled, and will pass quality control checks – all without the use of liquid cooling.

Removing liquid cooling from this application increases the quality of this production process, all while maintaining the same production levels.  And, this customer is now considering the use of a “stronger” Vortex Tube solution which may provide for increases in the throughput of the production process.

To discuss a similar application, or any application in need of a compressed-air based solution, contact an EXAIR Application Engineer.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Cold Gun Keeps Analyzer 31°F Cooler to Prevent Failure

A few months ago I had worked with a customer on a finned heat sink, cooling application. The heat sink is part of their TOC analyzer which is a device that detects and measures total organic carbon levels found in a fluid sample. The part of the plant where the analyzers are located has several pieces of equipment generating heat in the ambient environment close to 110°F. When the temperature gets this high, the analyzers begin to overheat, resulting in faulty readings and they will ultimately shut down. They were wanting to install a device that could blow cold air across the heat sink on the analyzer to prevent it from overheating.

After discussing the application with the customer, I recommended our Model # 5315 Cold Gun Aircoolant System with two cold outlets. The Cold Gun produces a 50°F temperature drop from compressed air supply temperature and provides 1,000 Btu/hr. of cooling capacity. For example, if your compressed air supply temperature is 70°F you would effectively see 20°F air being discharged from the cold exhaust. The Dual Point Hose Kit splits the cold airflow into 2 separate streams, providing for a wider coverage area.

5315_SCGdual

Model # 5315 Cold Gun System with dual point hose kit

The customer decided to order a single unit and after a week of testing replied back…

“We tried one a week ago with excellent results! We are installing three more today.  The other five will be here today and tomorrow.

Thank you so much for your help! Our analyzer is running 31°F cooler than it had been with no more overtemp failures!”

It goes without mentioning, but this is the type of positive feedback we are thrilled to hear! It feels incredible when a customer takes time out of their busy schedule to acknowledge how EXAIR products provided the perfect solution for their needs!

BUT the story doesn’t end there… just last week, over 2 months since our last correspondence, the customer sent me another email that read…

“Just a follow up on the effectiveness of the cold air guns. We have not experienced a single failure of our TOC analyzers since the guns were installed two months ago.

The cold air solved the problem of our analyzer overheating — even during the hottest part of the summer.

Thank you for your excellent recommendation!”

I let the customer know how much we appreciated the awesome news and how happy we were to be able to solve their problem. At the end of the day, that’s what we strive for, to provide the best and largest selection of Intelligent Compressed Air Products on the market today.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

 

 

 

 

Cooling a Thermal Manikin After a Fire

Not to be persnickety, but there is a difference between mannequins, life size model for displaying or tailoring clothes, and manikins, an anatomical model used for testing and teaching, usually with movable joints. (The enunciation is exactly the same though).  A lab designed a test for thermal protective clothing.  They had a manikin that was 6 feet in height and had 120 copper slug sensors located all over its body. The sensors would record the temperature gradients on the surface of the manikin, representing skin exposure to heat.  They would dress their manikin with thermal protective clothing from head to toe and expose it to intense fires at various temperatures and exposure times.  After each test was completed, they would record the results and cool the manikin to 26 deg. C before they started the next fire test.  These results were used for safety limits to protect wearers from second and third degree burns, very important in keeping firefighters safe.

Fire Suit under test

Fire Suit under test

In their application, they were looking to cool the sensors on the manikin as quickly as they can to increase test cycle rates. Initially they used a “cool down” area fitted with fans to blow air across the manikin.  The problem was that it took too long to cool to the 26 deg. C mark required in their testing protocol.  They decided to manually use an air gun to blow compressed air across the sensors to increase cooling.  This did reduce the cycle time, but because of the force created by the air gun, some sensors would shift and be out of calibration.  This was a huge concern for the test lab.

The design of the copper slug sensor has a small piece of copper set inside a silicone holder. To isolate the copper metal, there are small ruby spheres between the holder and copper slug.  This creates an air gap around the copper slug to help increase sensitivity to temperature changes.  A thermocouple is attached to the back side of the copper slug for analytical measurements.

Adjustable Spot Cooler

Adjustable Spot Cooler

After they discussed their application with me, I suggested the model 3725 Adjustable Spot Cooler. This base unit comes without a magnetic base and hose kit, which makes it lighter in weight. The customer could easily attach it directly to their compressed air line, replacing the air gun that was damaging the sensors.  The Adjustable Spot Cooler incorporates the Vortex Tube which makes standard compressed air into cold air.  With a turn of a knob, they could control the temperature and the velocity of the cold air.  This feature was key in determining just the right amount of force to not affect the calibration of the sensors.  An added benefit of the Adjustable Spot Cooler is if you reduce the amount of outlet cold air, the temperature will decrease even more.  This feature allowed the customer to reach their target much more quickly and without damaging the sensors.

If you need to cool things down in your application, you can contact an Application Engineer at EXAIR. We have many different styles and combinations of Vortex Tubes and Spot Coolers to give you the right form of cooling, whether it is a mannequin or a manikin.

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

 

DDI-2007-Burning Man by Interpretive Arson.  Common License.

Controlling Supply Pressure, Controlling Flow

“What is the lowest operating pressure and what kind of force can I expect?”. This is common question we get at EXAIR and the simple answer – it depends. Okay, that’s not so simple and it does matter what EXAIR product you are considering.

Take for example some of the vortex tube based cooling products, like our Cold Gun for dry machining and Cabinet Cooler Systems to purge and cool electrical enclosures. These particular products are designed to operate at 80-100 PSIG for optimal performance and efficient cooling capacity. They can be operated at lower pressure but their effectiveness and performance are reduced.

Most other products, and the problem they are solving vary in the amount of pressure needed for success. In many cases, the simplest method would be to use a pressure regulator. By incorporating a pressure regulator in a blowoff application, for example using our Air Nozzles or Safety Air Guns,  adjusting the supply pressure is the easiest way to control the output velocity and force of the airflow. Many applications don’t require full line pressure to achieve the desired result and operating at lower pressure provides a way to reduce compressed air usage and lower energy costs.

Click on picture for more information

Pressure Regulator with gauge for simple supply adjustment

Another way some of EXAIR’s products allow for easy adjustment is by incorporating a replaceable shim. Take for example our Air Knives – All of our Air Knives are shipped from stock with a .002″ shim installed. We offer Shim Sets for our aluminum knives that include a .001″, .003″ and .004″ shim  that allows you to either reduce the gap and cut your air usage and force in half. By installing the thicker shims, you can increase these properties by 1.5 times for the .003″ shim or double by installing the .004″. For our stainless steel knives, we offer shim sets which include (3) .002″ which can best stacked to provide more force and flow.

sak-shims

Super Air Knife shims

Our Air Amplifiers feature patented shims that allow for the similar adjustments, resulting in large volumes of outlet airflow.

Super Air Amplifer w- shims

Super Air Amplifier and optional shim set

Our Air Wipes, which perform similar to our Air Knives but produce a 360″ ring of air to treat the surface of a hose , pipe, tube, etc. , are also shipped with .002″ shim installed with optional shim sets available.

gh_SAWshimsets_750x696p

Shims for our Super and Standard Air Wipes

We also offer replaceable shims for our 1″ and 2″ Flat Super Air Nozzles for those applications requiring more of a focused airflow that needs that extra bit of force, like when trying to blow heavy grit off of a chain or blow reject parts from a conveyor.

Model 1126 (Zinc Aluminum) or 1126SS (316SS) 1" Flat Super Air Nozzles (left) have replaceable shims (middle), same as Model 1122 (Zinc Aluminum or Model 1122SS 2" Flat Super Air Nozzles (right.)

1″ and 2″ Flat Super Air Nozzles provide laminar airflow that can be easily adjusted.

As you can see, there are some viable options to fine tune your EXAIR product to provide the optimal performance. If you need any assistance or would like to discuss the specifics of a particular application, give us a call.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

 

 

 

 

Posted in Compressed Air. Tags: , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , . Leave a Comment »
%d bloggers like this: