Filter Element Coding for Variant-Safe Housing Assembly
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Solution Overview
Problem
Existing filter systems and elements lack a cost-effective mechanism for providing multiple variants without requiring extensive tooling efforts and complex production processes.
Innovation Solution
A filter system and element design featuring a filter bellows with coding elements and pins that engage on the outside of the end cap and housing, allowing for multiple variants through angular positioning without the need for tool changes, ensuring proper alignment and preventing incorrect assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional filter systems use fixed tooling for each variant, then manufacturing precision is maintained, but device complexity and production costs increase significantly
Solution Approach 1:
The housing is designed with a universal coding structure that can accommodate multiple filter element variants through different coding element configurations. A single housing design serves multiple functions by working with various coding patterns (different numbers, positions, and arrangements of coding elements), eliminating the need for variant-specific tooling while maintaining manufacturing precision.
Solution Approach 2:
The system transitions from static, fixed tooling for each variant to a dynamic coding structure where the number, position, and arrangement of coding elements can be varied. This dynamic approach allows the same housing and installation tool to adapt to different filter element configurations, reducing tooling complexity while preserving precision.
2Adaptability or versatility
If multiple coding elements are added to the filter element, then adaptability for different variants is improved, but manufacturing precision requirements increase
Solution Approach 1:
The coding system is segmented into multiple independent coding elements that can be individually positioned on the filter element. Each coding element represents a discrete piece of information about the filter variant. This segmentation allows for flexible combination and arrangement of coding elements to differentiate variants while maintaining manageable manufacturing precision requirements for each individual element.
Solution Approach 2:
The coding elements are positioned asymmetrically at specific locations and angles on the filter element relative to the housing. This asymmetric arrangement provides unique coding patterns for different variants, improving variant differentiation capability. The asymmetric positioning also simplifies the installation process by providing clear alignment references, thereby maintaining manufacturing precision without requiring excessive tolerance control.
3Measurement precision
If coding elements are positioned at specific angles and locations, then alignment precision is improved, but ease of manufacture decreases
Solution Approach 1:
The coding elements are pre-positioned and fixed on the filter element at the correct angles and locations before the filter element is installed in the housing. This preliminary action ensures that when the filter element is installed, the coding elements are already in their precise final positions, achieving high alignment precision without requiring complex adjustment mechanisms during installation. The pre-positioning simplifies the manufacturing process by allowing coding elements to be attached to a stable substrate (the filter element) rather than to the housing itself.
Data Source
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AI summary
The invention relates to a filter system (100) comprising a filter element (10), wherein a recess (30) is arranged on an outside (22) of the filter element (10). At least one coding element (32) is arranged on a circumference (24) of an end cap (18, 20) of the filter element (10). At least one coding pin (130) is arranged on an inside (114) of a bottom housing part (112) for cooperating with the recess (30) when the filter element (10) is inserted in the housing (110). The bottom housing part (112) comprises a circular shield (116) comprising a slot (132) extending in the axial direction (L), wherein the slot (132) is configured to receive the coding element (32) of the filter element (10) when the filter element (10) is inserted in the housing (110). The invention further relates to a filter element (10).