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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 - PowerPoint PPT Presentation
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Permanent HousingPermanent Housing for a Ceramic Oil for a Ceramic Oil
FilterFilter
Permanent HousingPermanent Housing for a Ceramic Oil for a Ceramic Oil
FilterFilter
MIM U702MIM U702Capstone DesignCapstone Design
rereNU Design TeamNU Design Team
Dale KochevarDale KochevarKelly SeitzKelly SeitzMarco SoliaMarco SoliaBarrett StraubBarrett StraubMatt WhalenMatt Whalen
MIM U702MIM U702Capstone DesignCapstone Design
rereNU Design TeamNU Design Team
Dale KochevarDale KochevarKelly SeitzKelly SeitzMarco SoliaMarco SoliaBarrett StraubBarrett StraubMatt WhalenMatt Whalen
April 15, 2008April 15, 2008April 15, 2008April 15, 2008
Problem DefinitionProblem DefinitionProblem DefinitionProblem DefinitionToo much motor oil is wasted each Too much motor oil is wasted each
year during the oil changing processyear during the oil changing process A significant amount of oil is lost when a A significant amount of oil is lost when a
traditional paper oil filter is thrown into a traditional paper oil filter is thrown into a landfill landfill
Standard paper oil filters must be replaced after Standard paper oil filters must be replaced after driving about 3,500 milesdriving about 3,500 miles
A quart of new motor oil can be refined from less A quart of new motor oil can be refined from less volume of recycled motor oil than crude volume of recycled motor oil than crude petroleumpetroleum
Environmental ImpactEnvironmental ImpactEnvironmental ImpactEnvironmental ImpactDrawbacks of paper filters:Drawbacks of paper filters: Roughly 500M used filters are thrown out each year Roughly 500M used filters are thrown out each year Not recyclable Not recyclable contaminate landfills with hazardous contaminate landfills with hazardous
waste:waste: Trace metals, chlorinated solvents, gasoline, Trace metals, chlorinated solvents, gasoline,
hydrocarbons, glycols and PCBs hydrocarbons, glycols and PCBs Contain up to ¼ gallon of used oilContain up to ¼ gallon of used oil
1 gallon of improperly managed used oil can 1 gallon of improperly managed used oil can contaminate 1M gallons of watercontaminate 1M gallons of water
Environmental ImpactEnvironmental ImpactEnvironmental ImpactEnvironmental Impact
Benefits of ceramic filters:Benefits of ceramic filters: Can be crushed, cleaned and recycledCan be crushed, cleaned and recycled Oil trapped in the filter can be reclaimedOil trapped in the filter can be reclaimed
Recycling 2 gallons of used oil can generate enough Recycling 2 gallons of used oil can generate enough electricity to run the average household for almost 24 electricity to run the average household for almost 24 hourshours
NEU has used SimaPro to prove the ceramic element NEU has used SimaPro to prove the ceramic element housing’s environmental superiority over standard filters housing’s environmental superiority over standard filters
1.1. Dirty oil enters honeycomb channelsDirty oil enters honeycomb channels
2.2. Oil passes through the wall Oil passes through the wall debris is trapped debris is trapped
3.3. Clean oil flows out channels through opposite Clean oil flows out channels through opposite open end open end
Ceramic Filtering ProcessCeramic Filtering ProcessCeramic Filtering ProcessCeramic Filtering Process
11 22 33
Dirty OilDirty Oil Clean OilClean Oil
Honeycomb cell pattern
Honeycomb cell pattern
NEU Ceramic Oil Filter NEU Ceramic Oil Filter BackgroundBackground
NEU Ceramic Oil Filter NEU Ceramic Oil Filter BackgroundBackground
NEU’s previous accomplishments:NEU’s previous accomplishments:
Confirmed that the ceramic Confirmed that the ceramic component is recyclable or component is recyclable or compactable.compactable.
Established that a ceramic oil filter Established that a ceramic oil filter can improve performance over that can improve performance over that of a conventional paper oil filter. of a conventional paper oil filter.
Produced a prototype that Produced a prototype that accomplished most project goals. accomplished most project goals.
Project GoalsProject GoalsProject GoalsProject Goals
To design the housing of the ceramic oil To design the housing of the ceramic oil filter with the following objectives:filter with the following objectives:
Ease of filter replacementEase of filter replacement No special tools requiredNo special tools required Design for the home mechanic Design for the home mechanic
Improve ManufacturabilityImprove Manufacturability Reduce part countReduce part count Use less costly manufacturing operationsUse less costly manufacturing operations
Make Production Cost Competitive Make Production Cost Competitive Minimize scrapMinimize scrap Make design robustMake design robust
rereNU Housing DesignNU Housing DesignrereNU Housing DesignNU Housing Design
Reduced part Reduced part countcount
Simpler partsSimpler parts Easier to assembleEasier to assemble
reNU DesignreNU DesignNEU DesignNEU Design
Engine Interface Adapter (EIA)
Engine Interface Adapter (EIA)
Inner Element SealInner Element Seal
Outer Element Seal
Outer Element Seal
Threaded RingThreaded Ring
FilterFilter
Spring Plate
Spring Plate
Anti-drainback Valve (ADV)
Anti-drainback Valve (ADV)
EIA SealEIA Seal
O-RingO-
Ring
Can
Can
SpringSpring
rereNU Design ComponentsNU Design ComponentsrereNU Design ComponentsNU Design Components
Oil Flow Through FiltersOil Flow Through FiltersOil Flow Through FiltersOil Flow Through Filters
NEU prototypeNEU prototype
Clean OilClean OilDirty OilDirty Oil
reNU prototypereNU prototype
rereNU Housing NU Housing DesignDesign
rereNU Housing NU Housing DesignDesign
Design ParametersDesign Parameters Bypass Valve Bypass Valve
Activation Pressure: Activation Pressure: 12 psi12 psi
Equivalent Flow RateEquivalent Flow Rate
at 3 GPMat 3 GPM Dimensions ≤ FRAM Dimensions ≤ FRAM
PH8A PH8A
Exploded reNU Design Exploded reNU Design
Engine Interface Adapter (EIA)Engine Interface Adapter (EIA) Machined FlatsMachined Flats 3.0”-8 UNC 2A3.0”-8 UNC 2A 1018 Low Carbon Stainless Steel1018 Low Carbon Stainless Steel
Threaded RingThreaded Ring Press Fit FRAM PH8A CanPress Fit FRAM PH8A Can 3.0”-8 UNC 2B 3.0”-8 UNC 2B 1018 Low Carbon Stainless Steel1018 Low Carbon Stainless Steel
SpringSpring ¼” Deflection at 12 psi (~40 lbs)¼” Deflection at 12 psi (~40 lbs)
CanCan FRAM PH8AFRAM PH8A Tin Coated Cold Rolled, Tin Coated Cold Rolled,
Aluminum Killed Drawn Quality Aluminum Killed Drawn Quality Sheet Steel (ASTM A599 and Sheet Steel (ASTM A599 and A1008M)A1008M)
rereNU Housing DesignNU Housing DesignrereNU Housing DesignNU Housing Design
reNU DesignreNU Design
rereNU Rubber NU Rubber ComponentsComponents
rereNU Rubber NU Rubber ComponentsComponents
5 rubber components:5 rubber components: 3 Seals3 Seals
EIA sealEIA seal Inner element sealInner element seal Outer element sealOuter element seal
O-ringO-ring Anti-drainback valve (ADV)Anti-drainback valve (ADV)
Material Selection:Material Selection: Nitrile rubberNitrile rubber
Most commonly used hydrocarbon Most commonly used hydrocarbon elastomerelastomer
Low costLow cost Oil resistantOil resistant Temperature range: -40°F - 225°FTemperature range: -40°F - 225°F
• Peroxide cured: -40°F - 275°FPeroxide cured: -40°F - 275°F High tensile strengthHigh tensile strength Resistance to abrasion, tearing, and Resistance to abrasion, tearing, and
compression setcompression set
Inner Element Seal
Inner Element Seal
Outer Element Seal
Outer Element Seal
Anti-Drainback
Valve (ADV)
Anti-Drainback
Valve (ADV)
EIA SealEIA Seal
O-RingO-
Ring
rereNU Pressure Release NU Pressure Release MethodMethod
rereNU Pressure Release NU Pressure Release MethodMethod
Normal oil flow Normal oil flow Filter clogged;Filter clogged;
Clean OilClean OilDirty OilDirty Oil
Bypass method in operation
Bypass method in operation
Testing Apparatus
Pressure Drop versus Flow Pressure Drop versus Flow RateRate
Pressure Drop versus Flow Pressure Drop versus Flow RateRate
Flow Rate (gpm)
Flow Rate (gpm)
Pre
ssu
re D
rop
(p
si)
Pre
ssu
re D
rop
(p
si)
3.753.75 4.424.42Pressure Drop at 3 gpm:
Pressure Drop at 3 gpm:
FRAM PH8AFRAM PH8A reNUreNU
Filtration EfficiencyE
ffic
ien
cy
%E
ffic
ien
cy
%
Particle Size (microns)
Particle Size (microns)
91%91% 89%89%Average Filtration Efficiency:
Average Filtration Efficiency:
FRAM PH8AFRAM PH8A reNUreNU
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
3 5 7 9 11 13
FRAM
reNU 1
reNU 2
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 PrototypePrototypeIdeal DesignIdeal Design
Manufacturing ProcessManufacturing ProcessManufacturing ProcessManufacturing Process
EIA AssemblyEIA Assembly Can AssemblyCan Assembly Spring Spring
AssemblyAssembly Filter AssemblyFilter Assembly
DeburrinDeburringg
TurningTurning DrillingDrilling AssembliAssembli
ngng
PaintingPainting Press-Press-
fittingfitting PackagingPackaging
Manufacturing Operations Manufacturing Operations NeededNeeded
Housing Housing SubassembliesSubassemblies
Cast EIA
Raw Ring
Can
Filter ASSY
Seals (3)
Ship
Packing & Shipping Box
Spring
Spring Plate
BenchTurn Inner
ThreadTurn ADV
GrooveTurn Outer
Thread
Drill Radial Holes
BenchAssemble EIA ASSY
Turn Thread Bench
Press-fit ring into can
PaintCan ASSY
Can ASSY
Incoming Material
Process Step
Completed SubASSY
Assemble Housing with filter
Package & Palletize
Ending Activity
Assemble Spring ASSY
7 Operations, 14 Total Processing Steps7 Operations, 14 Total Processing Steps
KEY
KEY
QuestionsQuestionsQuestionsQuestions
Current Crushing Technology
Filtration Efficiency
0
50,000
100,000
150,000
200,000
250,000
4 6 8 10 12
reNU 1 Sample E (unfiltered)
reNU 1 Sample F (unfiltered)
reNU 1 Sample G (filtered)
reNU 1 Sample H (filtered)
Cou
nt
per
CC
Cou
nt
per
CC
Particle Size (microns)
Particle Size (microns)
0
50,000
100,000
150,000
200,000
250,000
4 6 8 10 12
FRAM Sample A (unfiltered)
FRAM Sample B (unfiltered)
FRAM Sample C (filtered)
FRAM Sample D (filtered)
Cou
nt
per
CC
Cou
nt
per
CC
Particle Size (microns)
Particle Size (microns)
FRAM FilterFRAM Filter
re NU Filterre NU Filter
NEU Ceramic Oil Filter NEU Ceramic Oil Filter BackgroundBackground
NEU Ceramic Oil Filter NEU Ceramic Oil Filter BackgroundBackground
Traditional paper filter
Traditional paper filter
NEU’s latest prototypeNEU’s latest prototype
Clean OilClean OilDirty OilDirty Oil
NEU Ceramic Oil Filter NEU Ceramic Oil Filter BackgroundBackground
NEU Ceramic Oil Filter NEU Ceramic Oil Filter BackgroundBackground
Traditional FRAM Paper Filter
Traditional FRAM Paper Filter
reNU PrototypereNU Prototype
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