Clean Your Machine Coolant with the EXAIR Chip Trapper

Do 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 answered yes to any of these, EXAIR has a product for you; the Chip Trapper System.

EXAIR's new Chip Trapper
EXAIR’s Chip Trapper

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, 55 Gallon, and 110 Gallon. 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.

Chip Trapper Family
30, 55, 110 Gallon Chip Trapper!

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.

Take a look at this customer Video as they use the Chip Trapper to do their yearly deep clean and coolant Swap on their CNC Mill! (The Chip Trapper is used starting at the 3:17 mark in the video). This is also a very good video for further education on coolants and equipment. 

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.  

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

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.

Jordan Shouse
Application Engineer

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Twitter: @EXAIR_JS

Usefulness of a Coanda Profile

How did a past inventor help generate efficient compressed air products for EXAIR?  In the early 20th century, Henri Coanda who was a Romanian aeronautical engineer that built an experimental Coanda-1910 airplane.  There are some debates if the airplane actually flew, but he invented a curved surface for a wing to generate a Coanda effect. The Coanda effect is the “tendency of a fluid jet to stay attached to a convex surface”1.   Thus, a moving stream of fluid will follow the curvature of the surface rather than continuing to travel in a straight line.  The Wright Brothers who flew the first airplane in the state where EXAIR is located, Ohio, used the Coanda effect to create lift.  With a curved profile, the air will adhere to the surface, causing a low pressure which makes the airplane fly.

Standard Air Knife

Super Air Amplifier with shims

EXAIR uses this Coanda profile to make some of our Intelligent Compressed Air Products™.   Like the airplane wing, our curved surface will also create a low pressure.  How does this help?  Well, high pressure will always travel to low pressure.  Instead of lift, we use the low air pressure to entrain ambient air.  This ratio is what we call the amplification ratio.  The higher the amplification ratio, the higher the efficiency for a blowing device. Two main compressed air products that EXAIR manufactures use this type of profile; Air Knives and Air Amplifiers.  I will cover both below.

Compressed air flows through the inlet (1) to the Standard Air Knife, into the internal plenum. It then discharges through a thin gap (2), adhering to the Coanda profile (3) which directs it down the face of the Air Knife. The precision engineered & finished surfaces optimize entrainment of air (4) from the surrounding environment.

The Air Knives that use the Coanda profile blows air along the length of the knife at a 90o angle from the exit.  We offer two types; the Standard Air Knife and the Full Flow Air Knife.  The Standard Air Knives are made in Aluminum or Stainless Steel with blowing widths up to 48” (1219mm).  The inlet ports are at each end; so, the overall length is 1” (25mm) longer.  The Full Flow Air Knives have the port or ports on the back.  The air blows out the entire length of the air knife.  The maximum length is 36” (914mm).

Both types of air knives use the Coanda profile to generate a low pressure as the air exits the gap and “hugs” the curve (reference photo above).  This low pressure draws ambient air into the air stream at a 30:1 amplification ratio for both the Standard Air Knife and Full Flow Air Knife.  So, for every one part of compressed air, we entrain 30 parts of ambient air.  Besides efficiency, it also adds mass to the air stream for a hard-hitting force.  With this engineered profile, the air stream is laminar which gives a consistent force across the entire length and reduces noise levels.  Not only will they save you money,  but they are also OSHA safe.

Air Amplifiers use the Coanda Effect to generate high flow with low consumption.

The Air Amplifiers use the Coanda profile in a circular form to pull in dramatic amounts of free surrounding air.  The Coanda effect is able to generate a low pressure to blow air for cooling, cleaning or removing smoke and debris efficiently and quietly.  The Air Knives above blow a flat stream of air while the Air Amplifiers will blow a conical air stream.  They can reach amplification ratios up to 25:1. The Super Air Amplifiers use a patented shim to increase efficiency.

Unlike fans, they blow a laminar air stream for quick cooling.  They do not have any moving parts or motors to wear, so they are very quiet.  EXAIR manufactures five different sizes from ¾” (19mm) to 8” (203mm).  The Adjustable Air Amplifiers have a plug that can be adjusted to control the blowing force from a breeze to a blast.  For cleaning surfaces, this is a nice feature to “dial” in to exactly what you need.  We also manufacture five different sizes in aluminum and stainless steel ranging from ¾” (19mm) to 4” (102mm).  Both Air Amplifiers can be attached to ducts to remove debris, heat or smoke from the area.

Utilizing the Coanda effect allows for massive compressed air savings. Whether it is a flat or round air stream, EXAIR can do this with high amplification ratios.  If you would like to discuss further how our Air Knives or Air Amplifiers can help you in your applications, please contact us. An Application Engineer will be happy to help you.  History has shown us a way to increase efficiency when using compressed air.  And you can take advantage of it with the Coanda profile.  Thank you Mr. Henri Coanda.

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

 

1note – Wikipedia – Coanda effect

Super Air Amplifiers and Amplification Ratio

Super Air Amplifier Family

In the pneumatic industry, there are two types of Air Amplifiers.  One type will amplify the inlet air pressure to a higher compression.  The other type uses the inlet air pressure to amplify the air volume.  EXAIR manufactures the volume type called the Super Air Amplifiers™.

This change in air volume is called the amplification ratio.  So, what does this mean?  The definition of a ratio is the relation between two amounts showing the number of times one value is contained within the other.  For the Super Air Amplifier, it is the value that shows the amount of ambient air that is contained within the compressed air.  The higher the ratio, the more efficient the blowing device is.  With the EXAIR Super Air Amplifiers, we can reach amplification ratios up to 25 to 1.  This means that 25 parts of ambient “free” air is introduced for every 1 part of compressed air.

Air Amplifiers Are Great For blowing!

Why an EXAIR Super Air Amplifier?  Like a fan, they are designed to move air.  But fans use motors and blades to push the air toward the target.  The fan blades “slap” the air which creates turbulent air flows and loud noises. The Super Air Amplifiers do not use any blades or motors to move the air.  They just use a Coanda profile and a patented shim to create a low pressure to draw in the ambient air.  In physics, it is much easier to pull than it is to push.  The process of pulling air through the Super Air Amplifiers make them a more efficient, uniform, and quiet way to blow air.

Most people think that compressed air is free, but it is most certainly not.  Because of the amount of electricity required, compressed air is considered to be the fourth utility in manufacturing plants.  To save on utility costs, it is important to use compressed air as efficiently as possible.  In reference, the higher the amplification ratio, the more efficient the compressed air product.  Manufacturing plants that use open fittings, copper tubes, and drilled pipes for blowing are not properly using their compressed air system.  These types of products generally only have between a 2:1 to 5:1 amplification ratio.  The Super Air Amplifiers can reach a 25:1 ratio.

EXAIR manufactures and stocks five different sizes ranging from ¾” (19mm) up to 8” (203mm) in diameter.  Some of the benefits that the Super Air Amplifiers have is the inlet and outlet can be ducted for remote positioning.  They are very compact and can fit into tight places.  They do not have any moving parts to wear or need electricity to run.  They only need clean compressed air to operate; so, they are maintenance-free.

Another unique feature of the EXAIR Super Air Amplifier is the patented shim which optimizes the low-pressure to draw in more ambient air.   With extracting welding smoke, increasing cooling capacities, and moving material from point A to point B; the more air that can be moved, the better the performance.  And with the patented shim inside the EXAIR Super Air Amplifiers, it provides that.  As an added bonus, they are OSHA safe and meet the standards for noise level and dead-end pressure.

Super Air Amplifier Patented Shims

To explain things in every day terms; the amplification ratio can be represented by gas mileage.  Like your car, you want to get the most distance from a gallon of gasoline.  Similarly, with your compressed air system, you want to get the most for your pneumatic equipment.  An EXAIR Super Air Amplifier has a 25:1 amplification ratio.; so, in other words, you can get 25 mpg.  If you use drilled pipes, open fittings, copper tubes, etc. for blowing, then you are only getting 2 to 5 mpg.  If you want to get the most “distance” from your compressed air system, you should check the “gas mileage” of your blow-off components.  If you need assistance, an Application Engineer at EXAIR can help you to “tune up” your compressed air system.

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

EXAIR’s Chip Trapper Improves Material Recovery for Recycling

I recently worked with our Peruvian Distributor to help one of their customers solve an issue they were having with material recovery after a polishing operation. The company manufactures security locks for doors. During the manufacturing, one of the processes involves polishing the parts to a nice finish to ensure proper fit and provide a nice appearance for the finished product. Coolant is used to keep the temperature down during the polishing process. This coolant is then contaminated with leftover bronze debris that the company recycles.

The problem was that the process to filter the leftover bronze from the coolant was done by hand. This process, taking almost one hour to complete, was too time consuming and they were not able to recover 100% of the material. In looking for a better way to perform this process, they came across the EXAIR Chip Trapper.

The Chip Trapper was able to allow them to empty the entire coolant sump in less than 90 seconds. The bronze material contained within the coolant was trapped by the 5 micron filter bag inside of the drum, while the coolant passed through. They could then pump the clean coolant back into the drum and recycle the bronze trapped in the filter bag. Not only were they able to dramatically reduce the time it took to complete the process, but it also resulted in a much more effective method of reclaiming the material. No longer were they stuck with an inferior process and more time could be freed up to be spent on production.

Using either a standard or High Lift Reversible Drum Vac to provide the vacuum source, the Chip Trapper is capable of filling or emptying a 55 gallon drum in less than two minutes. It is able to pick up both the liquid coolant as well as any chips or shavings that are suspended in the coolant. The liquid is forced through a filter bag inside of the drum which contains any solid materials while allowing the coolant to filter out into the drum. Switching the knob on the Reversible Drum Vac and the directional flow valve to empty will allow the clean coolant to be pumped back out of the drum and reused.

chiptrapperfamily

After implementing the Chip Trapper in our own shop, we were able to increase the life of the coolant by 6x. In addition to the increased coolant life, a process that used to take up to 2 hours per machine now takes less than 10 minutes. The Chip Trapper quickly and easily pays for itself.

The Chip Trapper is available in either 30, 55, and 110 gallon systems. It’ll also come with (2) 5 micron filter bags, other filter bags are also available ranging from 1 micron up to 200 micron filtration. Using a simple detergent, the filter bags can be washed out, cleaned, and reused multiple times. With no motors or impellers to clog or wear out, as well as no electricity requirement or shock hazard, the Chip Trapper comes with our standard 5-year Built to Last Warranty. Do yourself (and your machine operators) a favor and get a Chip Trapper on order today. They’re in stock, ready to ship and start saving you time and money!

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