In the previous article, we looked at the importance of the data collection phase in the process of designing a high performance hydraulic filter.
This initial phase allows us to accurately define the characteristics and operating conditions required to develop a product that meets the specific needs of each application.
This month we will focus on the second phase of our five-step design process: the design step.
Design Step: Data, experience and creativity in action
The design phase, or ‘design step’, is where the data collected is transformed into a concrete design.
It is at this stage that the experience and ingenuity of our designers come together to develop hydraulic filters that not only meet the required technical specifications, but also anticipate the future needs of the industry.
Using the digital data sheet created during the data collection phase and all ancillary information, our designers begin to define the dimensions, materials and configuration of the filter.
This stage is essential to ensure that each filter designed by UFI Filters Hydraulics is capable of operating under the extreme conditions of the project, maintaining high performance and ensuring good reliability throughout the life of the filter.
When designing a new filtration system, we consider five basic macro categories:
Each point is closely related to the others. For example, increasing the thickness of components to improve structural strength can lead to increased costs and a possible reduction in internal fluid dynamics. UFI Filters Hydraulics designers are able to develop optimised solutions that balance these aspects to ensure high quality and competitive products on the market.
External structural design of the filter
The structural design of the filter is based on several key components:
- Static pressure resistance: the filter must withstand overpressure relative to the nominal working pressure.
- Dynamic pressure resistance: the filter must be able to cope with pressure variations to avoid fatigue failure.
- Seals: must provide a seal against internal pressure.
- Prevention of cracking or breakage: the filter must be able to withstand vibration during operation.
- Protection against corrosion and other external phenomena: these phenomena can affect structural strength.
The designer’s choices
The designer must consider several aspects to ensure the strength and functionality of the filter:
- Materials and manufacturing methods: The mechanical properties of the filter depend on the material and the manufacturing method. The designer draws on experience, supplier support and international standards.
- Local production: when working globally, it is often necessary to adapt materials and standards according to the production region (APAC, EMEA, etc.).
- Post-manufacturing treatments: if required, post-manufacturing treatments such as heat treatments, surface coatings or chemical treatments can be applied to improve strength and mechanical properties.
- Geometries and functional parameters: define the correct geometry and assembly parameters, such as tightening torque, to ensure optimum performance.
Designed for filtration performance
Key factors in the design of the filter element include
- Required oil cleanliness.
- Minimisation of pressure drop.
- Filter element life.
Taking these factors into account, the designer selects the most appropriate UFI formula and defines the optimum element geometry to improve performance and reduce internal pressure drop.
Tools available to the developer
In addition to his own experience, the designer has several tools at his disposal to facilitate his work:
- 3D CAD software: essential for visualising components and quickly producing technical drawings to share with customers and suppliers.
- Internal manuals and guidelines: useful for preliminary assessments of geometric characteristics and solutions already adopted.
- Database of previous tests: makes it possible to evaluate the performance of solutions already implemented.
If required, UFI Filters’ R&D department with qualified staff can assist the designer in the development of new advanced solutions, such as innovative filter media.
Conclusion and next steps
The design step is a crucial phase that transforms the collected data into tangible solutions that are ready to be tested and validated. In the next article, we will look at the next steps in our design process, including prototyping and validation testing.
Stay tuned to learn more about the next steps in our design process.