Acute-Angle Microscreen Filter Elements for Metalworking Fluids
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Solution Overview
Problem
Metalworking facilities face challenges in maximizing the useful life of lubricating fluids due to contamination from metal chips and particulates, which interfere with recirculation and cause undesirable biological activity, and existing filtration systems are inefficient and difficult to service.
Innovation Solution
A filtration system with filter elements constructed using a microscreen filter affixed to a wire mesh support structure, arranged in cells with filter surfaces oriented at an acute angle, providing increased effective filter area and ease of servicing, and utilizing a filter aid to enhance microfiltration and prevent bypassing of unfiltered fluid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional filtration systems are used, then fluid filtration is provided, but the systems are inefficient and difficult to service, resulting in production downtime
Solution Approach 1:
The filtration system is divided into multiple independent filter cells, each containing filter elements that can be individually accessed and serviced. The frames are arranged in cells with filter surfaces oriented at an acute angle, allowing technicians to service specific filter elements without shutting down the entire system, thus improving both filtration efficiency and ease of maintenance.
Solution Approach 2:
The filter elements are designed with dynamic accessibility - the acute angle orientation and cell structure enable filter elements to be removed and replaced during system operation. This dynamic servicing capability eliminates production downtime while maintaining continuous filtration of the metalworking fluid.
2Reliability
If filter elements with high filtration area are used, then particulate removal is improved, but the complexity of the filtration system increases
Solution Approach 1:
The filter elements utilize the acute angle orientation in the third dimension to maximize filtration area within the available tank space. By orienting filter surfaces at an acute angle rather than parallel to the tank walls, the system achieves high filtration area without increasing the horizontal footprint or overall system complexity.
Solution Approach 2:
Multiple filter elements are nested within compact frame assemblies, with each frame containing multiple filter surfaces. This nested arrangement allows high total filtration area to be achieved within a compact structure, maintaining system simplicity while maximizing particulate removal efficiency.
3Area of stationary object
If microscreen filters are used instead of perforated plates, then effective filter area is increased, but support structure requirements increase
Solution Approach 1:
The filter element combines microscreen filter material with a wire mesh support structure, creating a composite element that provides both the high filtration area of microscreen and the structural strength of wire mesh. This composite construction eliminates the need for heavy perforated plate support structures while maximizing effective filter area.
Solution Approach 2:
The microscreen filter material provides a porous structure with high surface area for filtration. The porous nature of the microscreen allows it to effectively capture particulates while the wire mesh backing provides the necessary mechanical strength, reducing support structure requirements compared to solid perforated plates.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively removes particulates and extends the life of metalworking fluids by enhancing filtration efficiency, reducing downtime, and ensuring clean recirculation while maintaining system balance and preventing contamination buildup.
Implementation Method 1
The filter elements adapted for use in the system of the present invention are constructed by affixing a microscreen filter to a wire mesh support structure
Implementation Method 2
utilizing a filter aid to enhance microfiltration and prevent bypassing of unfiltered fluid
Implementation Method 3
a plurality of frames of filter elements are arranged in cells in which the filter surfaces of each member frame are approximately parallel to one another. The cell is disposed such that the filter surfaces of each member frame are oriented at an acute angle with respect to the longitudinal axis of the drag-out tank within which they are installed
Data Source
AI summary
A filtration system for metalworking fluids has panel filter elements arranged in cells in which the filter frames and panels are approximately parallel to one another. The filter frames are disposed such that the filter surfaces are oriented at an acute angle with respect to the longitudinal axis of the drag-out tank within which they are installed. The filter elements are constructed by affixing a microscreen filter to a wire mesh support structure. The wire mesh structure provides as much support as the perforated plates of the prior art, while featuring significant gains in effective filter area when compared with perforated plate constructions.