1 year ago

MDA Technologies 2/2014

MDA Technologies 2/2014

machine elements

machine elements cross-sections along the pleat. Many market players just use conventional wire mesh here which causes pressure losses, turbulence and dead-spaces, due to the woven structure. The combination of integrated drainage layer and the tried and tested stainless steel wire mesh ensures free flow with very low differential pressure coupled with high pleat stability (Fig. 05). The optimised and integrated drainage layers are produced for specific applications. 04 Comparison: Standard versus optimised drainage layer 05 Flow through wire mesh with and without integrated drainage layer 06 Comparison of the differential pressure graph: standard versus Optimicron Optimicron at a glance The new Optimicron filter series from Hydac has a wealth of new features and innovations (patents applied for). The increased filtration rating range means that the customer can achieve optimum fluid cleanliness for his special application. High contamination retention rates and therefore long filter element service life are achieved as a result of the efficient particle retention thanks to the graduated filter layer structure. The innovative outer wrap with oval perforations provides excellent tear resistance and indicates at first glance that it is a genuine element. Furthermore the Helios pleating increases the available area of incident flow and compared to standard pleating, this brings advantages in terms of differential pressure, particularly when subject to high loads. In addition, the optimised and integrated drainage layers on the upstream and downstream sides increase the flow cross-section as well as reduce the pressure drop significantly. The oval perforation makes the element immediately identifiable as an original Optimicron element. In addition, the wrap can be individually customised using high quality multicolour printing. Another innovation is the new and unique pleat geometry. The Helios pleat (patent pending), taking its name from the Greek sun god, features alternate high and low pleats. This special pleat geometry significantly increases the area for the incident flow and reduces the flow speed between the pleats (Fig. 03). This results in improved flow and consequently reduced differential pressure. If the system is subject to high loads, then with a standard pleat design, the pleats become compressed, the sides stick together and accordingly the differential pressure increases. The Helios pleating counteracts this compression because the smaller pleats support the larger pleats and help maintain a gap between them. This produces a large surface area for incident flow even under high load conditions. Therefore this produces consistently lower pressure drops. In the Optimicron filter element a new type of drainage layer (patent pending) is incorporated on the upstream side. The special, asymmetric design (Fig. 04) of this layer allows channels to develop through which the fluid can flow uninterrupted. This provides excellent drainage along the pleat. A further innovation in the new Optimicron is the newly developed integrated drainage layer on the clean side of the filter element (patent pending). This ensures that fluid flow is channelled into large flow Some examples of energy saving in practice During tests, it was shown that Optimicron elements have up to 30% lower differential pressure in comparison to filter elements typically available on the market. Fig. 06 shows the differential pressure graph for a Optimicron® element compared to a standard filter element. The area under the curve illustrates the work which must be done to overcome the pressure drop which exists. The difference between the two areas (cross-hatched area) therefore represents the work which can be saved through the use of Optimicron elements. The table shows two typical applications of hydraulic filters from real life. The first example concerns a mobile machine with a flow rate of 500 l/min across the filter element. The filter element is changed after 1,500 operating hours and the final differential pressure is 5 bar. The energy saving achieved by using Optimicron filter elements is 246.5 kWh. When translated to fuel consumption, there is a saving of 41 l diesel fuel per filter element. 52 MDA Technologies 2/2014

machine elements Application Mobile Industrial Size 0660 0660 Filtration rating 20 µm 20 µm Flow rate V‘ 500 L/min 500 L/min Filter change t 1 1 500 h 3 000 h Initial differential pressure standard filter p a 0,58 bar 0,58 bar Final differential pressure standard filter p e 5,0 bar 5,0 bar Initial differential pressure Optimicron® p a 0,41 bar 0,41 bar Final differential pressure Optimicron® p e 5,0 bar 5,0 bar Pump efficiency ηη 0,90 0,90 Required energy standard filter W 2 191,6 kWh 4 339,9 kWh Required energy Optimicron® W 1 945,1 kWh 3 847,0 kWh Energy saving ∆W 246,5 kWh 492,9 kWh Saving in diesel fuel (efficiency of diesel engine: 35%) V D 41,01 L – Table: Examples of energy saving in practice 07 The innovations of the Optimicron filter element in summary About Company name: Hydac International Headquarters: Sulzbach, Germany Employees: 7,500 worldwide Established: 1963 Products: hydraulic control and drive systems, including electronic controls and regulators for mobile and stationary machines The second example describes a stationary system with 500 l/ min and a change interval of 3,000 h. In this case the energy saving per filter element was as high as 492.9 kWh. This is equivalent to the average electricity consumption of a two-person household in two months [3]. The results indicate a definite energy saving potential if using the new Optimicron® filter element technology. This means that considerable energy can be saved in the form of either fuel or electricity when operating a hydraulic system with the aid of innovative Optimicron technology. This reduces not only the operating costs, but more importantly, valuable resources are conserved and harmful emissions are reduced. Consequently Optimicron® is a guarantee of sustainable filtration. Another practical way of benefiting from the new technology is to reduce the filter size. Depending on the application, a filter of a smaller size can be installed for the same differential pressure by using more energy efficient Optimicron elements. Economies on both the filter housing and the filter element can therefore be made. Fig. 07 shows a graphic summarising all the innovative features of the Optimicron filter element – a convincing overall performance. References: [1] German Federal Statistical Office: Prices – Data on Energy Price Development, Wiesbaden 2013, page 49. [2] U.S. Energy Information Administration: International Energy Outlook 2013, July 2013, page 1. [3] Page “Electrical energy requirement”. In: Wikipedia, The free encyclopedia. Revision number: 27. November 2013, 12:42 UTC. URL: http://de.wikipediaorg/w/index.php?title=Bedarf_an_elektrischer_ Energie&oldid=124888429, Retrieved: 3rd December 2013, 14:41 UTC. MDA Technologies 2/2014 53 W-E-S-t.indd 1 01.04.2014 11:06:28


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