Filter Device Coalescer Final Separator Positioning
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Solution Overview
Problem
Existing filter devices with a coalescer and final separator arrangement face challenges in ensuring easy mounting and reliable venting, particularly in multi-stage configurations, where incorrect installation can lead to air cushion formation and reduced filtration efficiency.
Innovation Solution
A Poka-Yoke system is implemented between the coalescer and final separator, ensuring a single predefined installation position through a positioning element and opening, aligning the final separator radially within the coalescer, with features like angular cross-section ribs and an insertion funnel to prevent material abutment and optimize venting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the final separator is installed without a positioning system, then the mounting process is flexible and simple, but the installation position may be incorrect leading to air cushion formation and reduced filtration efficiency
Solution Approach 1:
The positioning element and positioning opening automatically guide the final separator into the correct installation position within the coalescer, eliminating the need for external alignment tools or complex mounting procedures. The component self-aligns through the mechanical interface of the positioning features.
Solution Approach 2:
The positioning element on the final separator and the corresponding positioning opening in the coalescer act as intermediary features that mediate the installation process, ensuring proper alignment and position without requiring complex external fixtures or procedures.
2Ease of manufacture
If the vent opening is positioned at a lower location, then the structural design is simplified, but air collects above the vent opening forming an air cushion that reduces filter surface availability
Solution Approach 1:
The final separator is designed with an asymmetric angular cross-section rather than a symmetric circular shape. This asymmetry inherently positions the vent opening at the highest location when the positioning element engages with the positioning opening, ensuring proper air venting without requiring additional complex features.
3Productivity
If the final separator ribs are positioned without precise alignment, then the assembly process is faster and simpler, but coalescer material may abut against the final separator material reducing filter performance
Solution Approach 1:
The positioning element and positioning opening are pre-configured on the final separator and coalescer respectively, establishing the correct relative position before assembly is complete. This preliminary positioning ensures that when the final separator is inserted, the ribs are automatically aligned to prevent coalescer material abutment.
Data Source
AI summary
A filter device is disclosed. The filter device includes a coalesce and a final separator arranged one after another in a flow direction. The final separator includes final separator material and is arranged radially within the coalesce. The coalesce is configured hollow-cylindrical and includes a coalescer material and an external support structure with an upper coalescer ring and a lower coalescer ring that are connected with one another via axial coalescer ribs. A positioning element is provided on the final separator. A positioning opening is provided in a region of the at least one lower coalescer ring. The positioning opening is configured in a complementary manner to the positioning element and the final separator engages into the positioning opening in a mounted state with the positioning element and thereby aligns the final separator relative to the coalesce.