Have A Blast (Of Cold Air) With EXAIR Vortex Tubes & Spot Cooling Products

The operation of a Vortex Tube is one of the more peculiar phenomena in fluidics, and a particularly unique method of producing cold air. Since they don’t perform “heat transfer” in the classical sense (see below), there’s no RATE of heat transfer…they’re generating cold air, at rated flow and temperature, instantly.

Compressed air enters the Vortex Tube (blue arrow) where the Generator imparts a spinning motion to the flow, which continues towards the “hot end” (red ribbon). The flow is forced to change directions and continue spinning, flowing in the opposite direction (blue ribbon). It’s at this point that the flow gives up energy in the form of heat, which is exhausted through the Hot Valve (red arrows) while the cold flow makes its way to the opposite end, where it exits at temperatures up to 129F colder than the compressed air supply.

EXAIR Corporation’s Vortex Tubes come in a range of sizes & cooling capacities, and are integrated into a number of Spot Cooling Products which add convenience and flexibility to their operation. Consider:

  • Vortex Tubes themselves are perfect for the most basic of installations. Small and Medium models weigh only a few ounces; you can thread them directly onto an existing 1/8 NPT (Small) or 1/4 NPT (Medium) fitting, if you have one (or can get one) adjacent to where you want to blow the cold air. Hot and Cold Mufflers can be added for sound attenuation, and the Cold Caps have 1/4 NPT (Small) or 3/8 NPT (Medium) female threads if you want to use a short pipe or hose to direct the cold flow.
  • Most spot cooling applications are best handled with the higher air flows and moderate temperature drops associated with a Vortex Tube product set to a high cold fraction. We have three distinct products that have a pre-set, non-adjustable cold fraction, aimed at these situations:
    • Mini Cooler Systems are quiet, compact, and ready to install in minutes via a Swivel Magnetic Base. They’re ideal for cooling small tools, needles in industrial sewing machines, saw blades, or lens grinders, just to name a few of the more popular applications. These come with built-in hot muffler, and are available with a Single or Dual Outlet Cold Air Hose Kit.
    • For applications that call for a higher cooling capacity, we offer the Cold Gun Aircoolant Systems. These have a bar magnet built in to the Cold Gun itself, integral Hot and Cold Mufflers, and, like the Mini Coolers, come with Single or Dual Outlet Cold Air Hose Kits. They’re most popularly specified to replace mist coolant in machine tools, but are also used on routers, grinders, drills, larger saws, and even some non-machining applications like chill rolls and setting hot melt adhesives.
    • For even higher cooling capacities than that, the High Power Cold Gun can be used. Size-wise, it’s identical to the Cold Gun, but it generates twice the Cold Gun’s flow of cold air.
Mini Cooler (left) and Cold Gun (right).

One of the main advantages of using these Vortex Tube products with the pre-set higher cold fractions is the prevention of freeze-up…while the cold air generated is usually just a little below 32F (0C), ambient conditions in the areas where they’re used typically add enough heat to prevent mass freezing of any moisture condensed in the cooling process. A number of applications, however, do indeed call for much colder air flow than this, and for those, we’ve got the Adjustable Spot Cooler:

EXAIR Adjustable Spot Coolers can generate temperatures as low as -30°F (-34°C) instantly, and on demand.

Their versatility makes them a great “utility player” – when very cold air (well below zero) is needed, the Temperature Control Knob is turned counterclockwise. If another application calls for higher flow (like the Mini Coolers or Cold Guns), it can be turned clockwise for instant adjustment of flow and temperature.

Adjustable Spot Cooler Systems are available with Single or Dual Point Cold Air Hose Kits, and come with three Generators: 15 SCFM (installed), 25 SCFM, and 30 SCFM, to select the compressed air consumption, and hence, the overall flow range.

If you’ve got a spot cooling application, EXAIR Corporation has a Vortex Tube solution for you. Give me a call; let’s talk cold air!.

Russ Bowman, CCASS

Application Engineer
EXAIR Corporation
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EXAIR Mini Cooler Overview

I recently had a chat conversation with a customer who was looking to cool the tooling on his CNC router, mill and lathe in his small machine shop. As the day went on the tooling would begin to heat up, it would warp the bit, causing irregularities in the finished product. In some cases the tooling was getting so hot, it would actually break, creating a safety concern.

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Model 3925 Adjustable Spot Cooler System has a Dual Outlet Hose Kit for distribution of cold air flow to two points.

He had reviewed some of our cooling products and was thinking of using our Cold Gun in the application but was concerned with the air demand. The Cold Gun consumes 15 SCFM @ 100 PSIG and provides a 50°F temperature drop (from supply temperature) with 1,000 Btu/hr. of cooling capacity. The problem was that his compressor only produces a little over 9 SCFM. I explained that the existing compressor would in fact be undersized as it doesn’t produce enough volume to keep up with the demand of the Cold Gun.

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EXAIR Mini cooler with dual and single outlets

Due to the limited amount of compressed air available, our Mini Cooler System, Model #3808, would be the better solution. The Mini Cooler also provides a 50°F temperature drop with a little less cooling power, 550 Btu/hr., but this system only requires 8 SCFM @ 100 PSIG, falling within the existing compressor’s output capacity. The Mini Cooler also includes a magnetic base as well as flexible tubing to direct the cold air to the desired location, making it easy to move from machine to machine.

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EXAIR Mini Cooler with dual Points

For U.S. and Canadian customers, EXAIR offers a 30-day unconditional guarantee to try.

If you want to learn more about the EXAIR Mini Cooler or any cooling product, you can contact an Application Engineer.  We will be happy to help you.

Jordan Shouse
Application Engineer

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Applications for Vortex Tube Spot Cooling

The EXAIR Mini Cooler family is one of the many vortex tube based Spot Cooler products that EXAIR offers.  This is the smallest of the group coming in at 550 BTU/hr of cooling capacity.  The Mini Cooler Systems  are available in two options.

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EXAIR’s Mini Cooler is available with a single point hose kit or a dual point hose kit.

  • The Single Point Outlet option will give you ten inches of flexible cold outlet to easily position the cold air stream near the target point.
  • The Dual Point Outlet option gives ten inches of 1/4″ flexible outlet that then splits to two separate four inch lengths of 1/4″ flexible cold outlet hoses.
  • Both include point or flat fan tips for the cold air outlets
  • Both include a manual drain filter separator
  • both include the swivel magnetic base with 100 lb. pull magnet.

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The Single Point Mini Cooler with a Flat Fan Tip installed on a milling application where liquid coolant cannot be used due to material constraints.

The single point hose kit is ideal for small diameter milling or drilling applications where the cold air can cover the contact area of the cutter.  It can also be used on soldering, industrial sewing, ultrasonic welding, or even small punching applications to list just a few.

EXAIR’s Mini Cooler System w/ Dual Point Hose Kit keeping UHMW cool while being machined

The dual point hose kit is ideal for two separate small diameter cutters, one larger diameter cutter, rotary style knives where there material is being slit, or larger diameter multi-point ultrasonic welders/punches.

When using the Mini Cooler the adjustable cold outlet stays in place and can easily bend around fixtures, spindles, welding horns, or dye aligning pins.  The swivel magnetic base gives additional adjustment at the base of the cooler to aid in the versatility of this product.   To further the adjustability of the cooler the operating pressure can easily be adjusted to lower or raise the cooling capacity of the Mini Cooler to meet the demands of the precise application.

If you believe you have an application that would benefit from the use of a Mini Cooler, or you are unsure which product would be ideal for your application please contact an Application Engineer.  we are all here, willing to help however possible to get your application improved in both safety and efficiency.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

 

 

Going Outside The Box With Vortex Tubes

Among EXAIR’s comprehensive line of Intelligent Compressed Air Products, the Vortex Tube stands out as a unique, and fascinating, solution for a variety of applications requiring a flow of cold air:

  • Cabinet Cooler Systems: clean, cold air to protect electrical and electronic components housed in an enclosure.  Installs in minutes; no moving parts; reliable & maintenance free.
  • Cold Gun Aircoolant Systems:  Direct, focused flow of cold air to replace messy coolant in machining, cutting, drilling, grinding, etc., applications.  Integral magnet base for quick & easy installation; single or dual outlet hose kits; standard or High Power to meet any need.  Optimized flow for maximum cooling and freeze prevention.
  • Adjustable Spot Cooler: Similar to the Cold Guns in many ways, but with variable performance for specific applications.  Cold air to -30°F (-34°C) on demand.
  • Mini Cooler: Similar to the Cold Guns and Adjustable Spot Coolers – magnetic base mounting and single or dual outlet hose kits, but more compact.  Lower flows for smaller jobs.

Then there are the Vortex Tubes themselves…at the heart of all of these products, but perfectly capable all on their own.  In fact, in certain situations, “plain old” Vortex Tubes have been used to do the exact same jobs as all of the above products.  They can even be customized, in and of themselves, to meet specific installation, operation, and/or performance needs:

  • High Temperatures: It should come as no surprise that cold air is often needed because a heat-sensitive item is located in a high heat environment.
    • Vortex Tubes come standard with plastic Generators and Buna o-rings, which are good for ambient temperatures up to 125°F (52°C).
    • High Temperature Vortex Tubes are fitted with brass Generators and Viton o-rings for environments where the temperature can reach 200°F (93°C).

High Temperature Vortex Tubes are suitable for use in environments up to 200F (93C).

  • Preset temperature & flow: Many times, the ability to adjust the performance of a Vortex Tube is a big benefit, but occasionally it’s a liability.
    • I know none of your co-workers are like this (nor are mine) but I’ve heard of people who think they “know better” and are prone to tampering with something that is (or WAS) working just fine, thank you very much.
    • Perhaps you actually DO know better, through experimentation and experience, the optimal performance setting for your application.  Let’s say, for example, you install Vortex Tubes on a line of your products, and a technician has to “dial it in” to a specific Cold Fraction.
    • Any Vortex Tube can be fitted with a drilled orifice (or “Hot Plug”) to replace  the Hot Valve, which presets performance to a specific, non-adjustable value.  If you know the Cold Fraction you need, it’s as easy as that.  If not, it’s as easy as getting a stock Vortex Tube, setting the Cold Fraction where you want it, securing the Hot Valve in position (piece of tape works just fine,) and sending it in.

Preset Vortex Tubes feature a fixed plug, replacing the Hot Valve shown in this picture.

If you’ve got any other specific requirements – special materials, fittings, custom flow/temperature parameters, etc., give me a call; let’s talk.

Russ Bowman
Application Engineer
EXAIR Corporation
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