Three technologies from a single source
Today’s CNC machine shop owners take pride in providing a clean, safe workplace for their employees by investing in manufacturing equipment designed to protect their health and safety. One of the most challenging issues they face is mist and smoke created by the oil-based, synthetic or emulsion type coolants used in modern CNC machining. If left unabated, this mist hangs in the air and eventually settles on all surfaces including machines, walls, floors and people.
Breathing these vapors can cause serious respiratory problems, aggravate existing breathing conditions, and irritating the eyes, nose, throat and skin, leading to employee health problems and absenteeism. Slick, oil-covered floors present the risk of injuries from falls. All of which creates potential liabilities for the shop owners and problems with OSHA.
Even high-efficiency factory HVAC systems typically can’t keep the workplace free of these contaminants, which is why many shops invest in oil/coolant mist collectors. It’s important to note that not all oil/coolant mist collectors work the same way. The technologies behind the three most common types of oil/coolant mist collectors are: multi-stage, electrostatic and centrifugal. Each has unique characteristics that make it the best choice for specific CNC machining applications.
Multi-Stage Media Oil/Coolant Mist Collectors
LNS FOX WS2 oil/coolant mist collectors use a three-stage system that consists of an initial pre-filtration cartridge, a cyclonic separation chamber and a final stage filter. This results in achieving 99% filtration and residual oil mist concentration of only 0.2 mg/m3(milligrams per cubic meter). This level of efficiency is guaranteed to be consistent throughout the oil mist collector’s life. LNS oil/coolant mist collectors accommodate all machine types and processes using water-soluble, synthetic or neat oil coolants. The unique multi-stage design virtually eliminates noise and vibration. Furthermore, reduces energy consumption and provides verifiable, continuous filtration efficiency.
Filtration Stages
As oil mist is drawn into the collector, it passes through the proprietary, multi-layered pre-filtration cartridge. This cartridge consists of three filtering layers that remove solid particulates and entrain bulk liquids. At the same time, it agglomerates finer mist particles into larger ones. Overall efficiency at this stage is 92%.
In the second stage, oil mist droplets accumulated in stage one reduce further by means of inertial impaction. Whereas small dust particles and liquid droplets impact a deflecting surface, in this case a special impeller that creates a cyclonic effect. The particles are forced to a cylinder wall where they coalesce and are then captured.
The third stage uses a proprietary high surface area cartridge media filter to remove any remaining oil mist. This filter removes 99% of oil mist to exceed OSHA and NIOSH standards. Users can also add an optional 4th stage HEPA filter that removes 99.97% of cutting oil smoke particles.
Efficient Monitoring
An integrated pressure gauge monitors the condition of the stage three filter by measuring airflow. Routine maintenance consists of replacing the long-life filters that typically maintain efficiency for 3,000 – 4,000 hours. Average time to replace a filter is five minutes.
Because many shops have a wide variety of machine tools, LNS can match any CNC machine with appropriate oil / coolant mist collectors. The WS 2 Series has five models with 170 to 1250 CFM airflow rates. The WM Series are for larger or multiple machines with 2350 CFM to 7050 CFM airflow rates.
Electrostatic Oil Mist Collectors
Recent innovations by LNS take the electrostatic technology to the next level with the LNS Fox HE 1000. A 4-stage system that eliminates 98.3% of mist, smoke and odors from wet machining operations using straight oil. The first stage is a coarse metallic mesh pre-filter that traps tiny chips. In stage 2, a fine mesh pre-filter coalesces particulates. Stage 3 electrostatically ionizes and collects oil mist. In stage 4 a fine mesh post-filter completes the process before releasing clean air that exceeds OSHA and NIOSH guidelines for industrial air quality. The variable speed motor provides fine turning of the airflow to suit your application and maximize maintenance intervals. An optional, 100% recyclable HEPA fine filter further eliminates dry smoke.
Although all oil mist collectors require some maintenance, keeping the LNS Fox HE electrostatic system performing at peak efficiency requires as little as two filter cleanings a year, depending on the application. Save time by accessing different elements of the unit from one centralized location with the innovative dual door design. The wireless one-piece ionizer and collector cell is designed and manufactured by LNS for safe, quick, and easy maintenance.
Centrifugal Coolant Mist Collectors
Designed for water-based applications, LNS ChipBLASTER MB Series mist collectors apply centrifugal force to thrust coolant particulates to the outside of the housing. Coolant flows along the housing surface to exit through a specially designed port. As liquid drains from the collector, air flows through washable aluminum filters and clean air exceeding OSHA air quality standards is returned to the shop.
The permanent aluminum filters are easily removed for cleaning, on average, about once each year. Therefore, there’s no need to purchase disposable filters. A built-in pressure gauge lets you know when the filters need cleaning, and 3 mounting options insure the best fit for every application. To precisely match each CNC machine and its applications, there are 3 LNS ChipBLASTER MB models with 300, 700 and 1200 CFM airflow.
Your LNS representative, can help you select the oil/coolant mist collection system that’s right for your CNC machines. Call 513-528-5674 or email: allproducts-sales@LNS-northamerica.com