Haas Coolant System Design Features and Improvements
SITTING STILL AND LEAVING GOOD ENOUGH ALONE is just not in our nature here at Haas. For some machine tool builders coolant seems like an after thought, but not at Haas. We realize that the coolant system is hyper critical to efficient production in any shop. SIGNIFICANT IMPROVEMENTS TO OUR COOLANT systems nets vastly reduced maintenance requirements, and higher productivity for shops running Haas machines. Some of these design improvements were made to the coolant system inside the machines, while other refinements took place within the coolant tank itself. Our approach is to evaluate each component of the system, and then make measurable improvements to each one, which results in a significant improvement to the entire system. Here are the details of the latest improvements:
Haas coolant tanks have undergone a complete redesign. In the past, the in-tank pump filters and screens required frequent cleaning to prevent pump cavitation caused by insufficient coolant reaching the pump (this can seriously degrade pump performance). Filtration is now accomplished through a settling-style separation system that greatly reduces tank clean-out frequency, while maintaining pump performance.
The Coolant Pump
The coolant path in any machine begins at the pump. We've recently developed a high-performance, 3-phase coolant pump that outperforms - and is more reliable than - the previous 1-phase coolant pump. The results have been exceptional: Our testing and owner feedback show overall better performance, less noise and vibration, and greater reliability.
Haas now uses 100% polyurethane hoses in all of our coolant systems and accessories. Sure, they cost more, but they never harden or crack, regardless of the coolant being used, they outlast PVC and rubber-style hoses by years - and they resist kinking throughout their life cycle.
Capture and Return Coolant Mist to the System
with the Enclosure Exhaust System
Everyone has experienced the delay caused by waiting for coolant mist to clear out of a machine when you open the doors. Nobody wants to breathe that stuff, so the operators wait for the mist cloud to clear, or blow the cloud away using the air gun. What a waste of time! Sure, there are aftermarket systems out there to clear out that mist, but they are expensive, not easily integrated into the machine, and some don't have a filter, let alone one that can be easily cleaned.
Solution: The Haas Enclosure Exhaust System is a low-cost solution that immediately improves productivity by reducing the total machining cycle time. How it works is simple. A powerful, low-vibration fan pulls the coolant mist generated by the cutter out of the enclosure. The coolant-laden mist passes through two reusable wovenmetal filter panels, where the coolant coalesces and is allowed to return to the enclosure, while cleaned air is expelled out the top of the unit. The system integrates with the Haas control, turning on automatically when the spindle starts and off after the spindle stops. An onscreen icon alerts the operator when the filters require cleaning.
Result: Operators experience greatly reduced coolant mist when they open the machine door, and are therefore less likely to pause before leaning into the machine to remove the finished part. The system not only improves overall shop air quality, but also reduces health issues associated with inhalation of coolant mist. Even greater health gains may be realized by venting the Enclosure Exhaust System outside of the shop using standard 10" ducting.
Coolant Return Spillway
Coolant drains from the machine through a trough we call the "Return Spillway." We noticed that, after many hours of use, the area around the back of the machines became very messy from the splashing that occurred when coolant circulated back into the tank. Our solution: Design a NO-SPLASH spillway that greatly reduces this phenomenon and the associated evaporation. In addition, we include a filter basket to strain the coolant before it re-enters the tank.
Coolant Level Sensor
Haas coolant tanks not only keep chips out of the coolant system, but are fully integrated with the Haas control. A float level sensor keeps track of the coolant level in the tank, and displays this information in real time on the control screen. There's no need to guess, measure, or walk to the back of the machine to make a visual determination of the coolant level.
Coolant Tank Oil Skimmer
The Haas Coolant Tank Oil Skimmer is an integrated solution for keeping your coolant tank free of tramp and tap oils. The skimmer is easily and quickly installed onto the side of the Haas coolant tank. During operation, it extracts tramp oil from the coolant in the tank, and deposits it into a collection container.
Automatic Coolant Refill System
The Automatic Coolant Refill System is a new option for Haas machines that mounts to the handle of any standard Haas coolant tank. It automatically monitors the machine;s coolant usage, and then replenishes the tank with coolant mixed to the correct concentration. The system, when connected to a water supply, blends the coolant concentrate of your choice with water, and automatically dispenses the mixture into the coolant tank. The system saves hours of maintenance, while keeping the machinist at the front of the machine making chips, instead of at the back of the machine making a mess!
Flood Coolant Ring
Designed specifically for the new Haas 3-phase pump, our new coolant-delivery system features a rail-style, wraparound manifold ring that provides 360° of forceful coolant streaming through four specially designed nozzles. The system improves delivery of coolant to the cutting tool, and is easy to adjust.
Programmable Coolant Nozzle
The Programmable Coolant Nozzle is a multi-position nozzle that automatically directs coolant precisely at the cutting tool. The position of the nozzle is controlled via the program, saving operator time by eliminating constant adjustments. From customer feedback and close observation, we determined that the unit was positioned too far from the spindle, and its nozzle was a bit too long. We addressed these issues by moving the unit 8 inches closer to the cutter, and shortening the nozzle to reduce possible collisions with rotary tables, fixtures, and workpieces.
High-Pressure Coolant Pumps (TSC / HPC)
Our 300 psi (21 bar), Haas high-pressure coolant pump is used to force coolant through long drills and boring bars. Delivering high-pressure coolant to the cutting zone allows uninterrupted drilling or boring, with better surface finish and longer cutter life. Our pump eliminates the separate power supply requirements, takes up less space, operates quietly, and costs less.
TSC Pump / Self-Cleaning Filter
We looked at our TSC pump to determine if a good design could be made better...and we decided it could. At the bottom of the TSC unit is a mesh filter screen that serves as a pre-filter for the TSC gear pump. We wanted to protect the pump better to promote longer life of the gears and bearing journals, so we reduced the pre-filter mesh size from 70 to 150. The new filter is 2X finer, so it collects debris at 2X the rate of the old filter (that's good!)...and clogs at 2X the rate of the old filter (that's bad!). So we added an automatic backwash system that cleans the filter every time the pump turns off - that's good! But wait, there's more. To make sure the pump doesn't stop pumping due to a clogged screen, we added a vacuum sensor on the intake side of the pump to measure how dirty the filter is. When it reaches a threshold value, the vacuum switch sends a signal to the control and notifies the operator that it's time to clean the TSC filter and clean the tank.
Auxiliary Coolant Filter
The Haas Auxiliary Coolant Filter is a low-cost option that serves to filter coolant for either the low-pressure or high- pressure coolant pumps. We reviewed the design, and made several improvements. To make it easier to check the coolant flow rate and the condition of the filter bag, we added a view port in the housing lid. We also added a unique venturi valve that maintains the coolant level within the tank automatically.