SpindleSHOT Offers Improved Chip Control and Less Maintenance

All World Machinery Supply engineers have developed an innovative high-pressure coolant system set to debut at the 2024 International Manufacturing Technology Show (IMTS). With customizable features for more precise machining and an automatic self-cleaning filter for less maintenance, SpindleSHOT efficiently removes chips during deep drilling operations. SpindleSHOT can serve industries requiring high-precision parts, such as medical, aerospace and mold making, as well as manufacturers of workholding fixtures with internal porting.

Effective chip removal is essential for manufacturing tolerance. This prevents holes from being incorrectly sized due to chip clogging, which can also compromise the part’s surface finish and shorten tooling lifespan. Applying coolant at high pressure ensures a cleaner cut, enhancing tool performance and part accuracy.

A Winning Combination

After hearing customers repeatedly criticize existing competitive high pressure coolant systems for their excessive noise due to chain-driven mechanisms connecting the motor to the pump­, All World senior director of technology Darrell Janesak started investigating potential alternatives for coolant-through-spindle (CTS) systems in October 2020.

After a very strong customer response to All World's custom-designed hybrid hydraulic power units, such as ClampMax and CorePull for plastic injection molding, for their quiet operation, IoT technology, and cost-effective price, engineers wanted to design a CTS system with similar characteristics.

“We felt we could build a better product for the marketplace with more advanced features,” Janesak said. “It would be clean, quiet, convenient and a smaller package.”

Janesak planned to produce a budget-friendly base unit with the same robust qualities of CorePull and ClampMax. The goal was to combine a high-pressure pump with the precision thermal management of a Daikin chiller and superior control technology by ifm efector. Thanks to All World’s existing partnerships with ifm and Daikin, the system would be extremely cost effective. Engineers sourced a versatile coolant pump enabling customization of pressure settings from 200 up to 1,000 psi. Due to its compact design, the pump would fit in a variety of spaces.

Because customers needed coolant-through-spindle systems for different uses, Janesak designed two models to fit their needs. The SpindleSHOT basic model, without a tank, is suited for occasional use, and the SpindleSHOT+ comes with a tank to best suit applications requiring continuous use of a high-pressure coolant system.

With the blueprints in place, engineers developed and installed the first prototype of SpindleSHOT+ in October of 2023 at Arrow Workholding Solutions for a machine performing deep-hole drilling on fixtures. It replaced their former system, used sparingly due to noise.

“Operators love this new system because you cannot hear it running. The old unit was so loud. You knew when it was running, in every corner of the building and even the offices and bathrooms,” said Frank Grube, All World engineering manager. “With the new system, the noise level has been reduced by 90-95%.”

Self-Cleaning Filter

Not only does the pump deliver high pressure, but it also features advanced cyclonic (centrifugal) filtration technology, eliminating the need for traditional bag filters. By using centrifugal force coupled with turbulence, the pump separates and removes contaminants through a wire mesh filter. The automatic self-cleaning filter collects and expels chips from the coolant, directing them to the drain port and returning them to the dirty side of a coolant tank or chip conveyor. Engineers designed the centrifugal filter system to be clog-free with a steady flow rate.

This feature cuts additional costs by eliminating the frequent replacement and regular upkeep of expensive filter bags, reducing costs and minimizing maintenance. Arrow Workholding Solutions has saved time and money with the new system. In the company’s former CTS system, for example, they faced expenditures between $5 and $40 for each bag, with frequent monthly replacements during periods of heavy use, according to Arrow Workholding solutions production manager Dan Janczak.

Whereas a company with a traditional system might have to change a bag filter once a month, the self-cleaning filter in SpindleSHOT only requires a tank wipe-down after approximately six months to a year, saving money and time.

“Bag filters are not cheap. It is another maintenance point as well as a potential failure point,” Grube said.

“When a filter gets clogged and requires replacement, it’s not only costly but also time-consuming. It’s a mess, and no one likes dealing with it,” Janesak added.

Tank & Optional Accessories

Without a tank, the SpindleSHOT allows the incorporation of more features into the basic model, such as a wheel kit for easy transport for intermittent use on a variety of machines. With two available models, the tankless SpindleSHOT and the SpindleSHOT+, which incorporates a tank to the design, the customer can choose the appropriate model based on their volume and usage.

Both the models can also enable smart controls. Using an IoT-ready HMI/PLC operator control and smart sensors connected to an IoT-ready hub, the system can self monitor and perform tasks like motor reversal for filter cleaning when not in use. If high-pressure coolant is needed during purging, it will pause cleaning to provide coolant and resume cleaning afterward. Being IoT ready, it can integrate with factory-monitored systems for real-time sensor tracking.

The controls package offers multiple connectivity options, including Ethernet TCP/IP, Ethernet/IP, Modbus TCP, OPC UA, and CANopen. The user interface is notably intuitive, featuring a graphical display and powered by the ifm control package. Users benefit from extensive control features, such as real-time diagnostics and immediate access to instruction manuals. The system's status – encompassing pressure, flow rate and temperature – is easily monitored and diagnostics facilitate troubleshooting.

For applications requiring tight tolerances and materials impacted by small temperature fluctuations, three chiller options are available for the SpindleSHOT with tank: 1.8 kW capacity, 3.5 kW capacity, and 4.5 kW capacity. With the addition of a chiller, the SpindleSHOT can keep fluid temperature to within one-half of a degree Celsius and maintain temperature consistency.

Additional add-on accessories, such as Royal Filtermist units, collect fog during machining, and Variaxe oil skimmers remove oils and chips and then deliver clean coolant back to machines.

SpindleSHOT+ features a valve block for stepped pressure control with four easy-to-adjust preset settings. Additional pumps can also be added to provide multiple port capabilities for applications on machine tools that are utilizing high pressure coolant on multiple axes at the same time.

A Winning Design

Because of SpindleSHOT’s simplified design and All World’s familiarity with its components, Janesak said it required little adjustment during installation at the Arrow facility. The only modification was adding a larger lift pump system to keep up with the high-pressure pump’s output.

Ever since installing SpindleSHOT+ on a horizontal machining center, Arrow Workholding Solutions CNC machinist Bruce Knapek has been amazed by its quietness compared to the previous system. The noticeable reduction in noise level allows for conversations near the SpindleSHOT+, impossible before with the competitive unit. Knapek also appreciates the efficiency of the attached chiller in maintaining a consistent temperature. While other systems may have similar features, he highlights that SpindleSHOT+ accomplishes this at a more affordable price and with significantly lower sound levels. A smaller number of components not only reduces complexity but also diminishes the likelihood of failure, ensuring uninterrupted machine operation.

Showtime Ready

With the two models finalized and ready for market, SpindleSHOT+’s next stop will be its debut at IMTS. The customizable unit will be part of All World’s lineup of innovative, energy-efficient and IoT-ready machine accessory solutions designed to enhance manufacturing shop productivity.

Interested customers will be able to experience SpindleSHOT’s features and ease of maintenance in person at the show. Even with a user-friendly, human-machine interface powered by ifm controls and IoT integration, the lower price will surprise and delight customers.

With custom features, like the optional chiller at $4,000 to $5,000, the cost is significantly lower than competitors' systems, which can add about $12,000 to the cost of the base unit. Accordingly, the SpindleSHOT+ system brings an average price advantage of $16,000 to $17,000 due to its integrated cooling and cyclonic filtration, highlighting substantial market savings over the competition.

“Why would anyone opt to pay more for less value?” Grube suggested.