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