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Permanent Housing for a Ceramic Oil Filter

Permanent Housing for a Ceramic Oil Filter. MIM U702 Capstone Design re NU Design Team Dale Kochevar Kelly Seitz Marco Solia Barrett Straub Matt Whalen. April 15, 2008. Problem Definition. Too much motor oil is wasted each year during the oil changing process

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Permanent Housing for a Ceramic Oil Filter

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  1. Permanent Housingfor a Ceramic Oil Filter MIM U702 Capstone Design reNU Design Team Dale Kochevar Kelly Seitz Marco Solia Barrett Straub Matt Whalen April 15, 2008

  2. Problem Definition Too much motor oil is wasted each year during the oil changing process • A significant amount of oil is lost when a traditional paper oil filter is thrown into a landfill • Standard paper oil filters must be replaced after driving about 3,500 miles • A quart of new motor oil can be refined from less volume of recycled motor oil than crude petroleum

  3. Environmental Impact Drawbacks of paper filters: • Roughly 500M used filters are thrown out each year • Not recyclable  contaminate landfills with hazardous waste: • Trace metals, chlorinated solvents, gasoline, hydrocarbons, glycols and PCBs • Contain up to ¼ gallon of used oil • 1 gallon of improperly managed used oil can contaminate 1M gallons of water

  4. Environmental Impact Benefits of ceramic filters: • Can be crushed, cleaned and recycled • Oil trapped in the filter can be reclaimed • Recycling 2 gallons of used oil can generate enough electricity to run the average household for almost 24 hours • NEU has used SimaPro to prove the ceramic element housing’s environmental superiority over standard filters

  5. Ceramic Filtering Process • Dirty oil enters honeycomb channels • Oil passes through the wall  debris is trapped • Clean oil flows out channels through opposite open end Honeycomb cell pattern 3 2 1 Dirty Oil Clean Oil

  6. NEU Ceramic Oil Filter Background NEU’s previous accomplishments: • Confirmed that the ceramic component is recyclable or compactable. • Established that a ceramic oil filter can improve performance over that of a conventional paper oil filter. • Produced a prototype that accomplished most project goals.

  7. Project Goals To design the housing of the ceramic oil filter with the following objectives: • Ease of filter replacement • No special tools required • Design for the home mechanic • Improve Manufacturability • Reduce part count • Use less costly manufacturing operations • Make Production Cost Competitive • Minimize scrap • Make design robust

  8. reNU Housing Design • Reduced part count • Simpler parts • Easier to assemble NEU Design reNU Design

  9. reNU Design Components Spring Plate Spring Filter Can Threaded Ring Inner Element Seal Outer Element Seal Anti-drainback Valve (ADV) O-Ring Engine Interface Adapter (EIA) EIA Seal

  10. Oil Flow Through Filters reNU prototype NEU prototype Dirty Oil Clean Oil

  11. reNU Housing Design Design Parameters • Bypass Valve Activation Pressure: 12 psi • Equivalent Flow Rate at 3 GPM • Dimensions ≤ FRAM PH8A Exploded reNU Design

  12. reNU Housing Design reNU Design • Engine Interface Adapter (EIA) • Machined Flats • 3.0”-8 UNC 2A • 1018 Low Carbon Stainless Steel • Threaded Ring • Press Fit FRAM PH8A Can • 3.0”-8 UNC 2B • 1018 Low Carbon Stainless Steel • Spring • ¼” Deflection at 12 psi (~40 lbs) • Can • FRAM PH8A • Tin Coated Cold Rolled, Aluminum Killed Drawn Quality Sheet Steel (ASTM A599 and A1008M)

  13. reNU Rubber Components 5 rubber components: • 3 Seals • EIA seal • Inner element seal • Outer element seal • O-ring • Anti-drainback valve (ADV) Material Selection: • Nitrile rubber • Most commonly used hydrocarbon elastomer • Low cost • Oil resistant • Temperature range: -40°F - 225°F • Peroxide cured: -40°F - 275°F • High tensile strength • Resistance to abrasion, tearing, and compression set Outer Element Seal Inner Element Seal O-Ring EIA Seal Anti-Drainback Valve (ADV)

  14. reNU Pressure Release Method Filter clogged; Normal oil flow Bypass method in operation Dirty Oil Clean Oil

  15. Testing Apparatus

  16. Pressure Drop versus Flow Rate Pressure Drop (psi) Flow Rate (gpm) FRAM PH8A reNU Pressure Drop at 3 gpm: 3.75 4.42

  17. Filtration Efficiency Efficiency % Particle Size (microns) FRAM PH8A reNU Average Filtration Efficiency: 91% 89%

  18. reNU Prototype vs Ideal Design • Weight • Decrease to 1.67 lbs • Height • Decrease to 5.8 in • Functionality • Spring • Ceramic element • Rubber components • Press-fitting Ideal Design Prototype

  19. Manufacturing Operations Needed • Painting • Press-fitting • Packaging • Deburring • Turning • Drilling • Assembling KEY 7 Operations, 14 Total Processing Steps Manufacturing Process Housing Subassemblies • EIA Assembly • Can Assembly • Spring Assembly • Filter Assembly

  20. Questions

  21. Current Crushing Technology

  22. Filtration Efficiency FRAM Filter Count per CC reNU Filter Count per CC Particle Size (microns) Particle Size (microns)

  23. NEU Ceramic Oil Filter Background Traditional paper filter NEU’s latest prototype Dirty Oil Clean Oil

  24. NEU Ceramic Oil Filter Background Traditional FRAM Paper Filter reNU Prototype

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