Our preliminary idea is to use a combination of different sensors that could foresee when the mesh filter is about to fail or need of service which if not addressed at the appropriate moment can lead to making the filtration machine come to a complete stop. Next would be investigating and improving the signal response of the coolant/fluid leveling sensor system, which sometimes causes inaccurate readings due to some coolants/fluids making foam during the filtration process. And if not addressed this can lead to using excessive amount of filtration paper which tends to be expensive.

VOA

When compared to the competitors, our product offers affordability, ease of use and efficiency.

Table

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1. Affordability: Our product is affordable to the companies and users.

2. Ease of use: The function of the filter system will be simple in order to allow the user to fully understand how to utilize the machinery. There would also be an improvement in the aesthetics of the filter machine by using meaningful tactics in the design to ensure we grab the user’s attention.

3. Sources: The filtering machine is designed to filter different type of sources.

4. Particle Types: The filtering machine is designed to increase the efficiency in removing various types of particles from the different materials.

5. Customization: The design of the filter system is based on meeting the needs of the user.

6. Industries: There are various industries that utilize and rely on the Resy Filtering System.

7. Self-Cleaning: The filtering machine is designed to self-clean and requires low maintenance.

8. Durable: It is a durable product since it requires low maintenance.

9. Efficiency: The product is very efficient in removing any particles by using the filtering system.

10. Reliability: It is a reliable product since it is very efficient and functions properly.

11. Less Consumption: The design of the filtering system will allow for the product to decrease the amount of filter paper consumption.

Back to INDEX.

PROBLEM FORMULATION

BACKGROUND RESEARCH

Filters have been a crucial part of our human history. Believe it or not, ancient civilizations used a variety of techniques to filter out unwanted substances/impurities for things like drinking water. The earliest record of how humans used filters, dates back to around 500 B.C. where the Greek scientist Hippocrates invented the so-called Hippocratic sleeve, which consisted of a simple cloth back filter. After that there's records of the Egyptian civilization at 400 A.D. using a variety of methods to eliminate harmful bacteria from there drinking water, like I mentioned previously they used several techniques such as boiling the water, heating it in the sun, or submerged a hot iron into it. They also filtered impurities from their water by sifting it through sand and gravel. And obviously as time went on so did the innovation of humans, discovering filtration methods of separating the salt from sea water to more complex things like being able to purify contaminated water with the method of chlorination in the mid 19^th Century. Now currently with modern technology, humans have pushed the boundaries of filtration towards the sky, from coffee ground bean filters to filtering metal cuttings from the coolant that is used in machinery.

Furthermore, there is an abundant amount of filtrations systems. All of them having their specific area of filtering for example, the method in which how they filter, different types of filtering material, and what type of objects/impurities the filtration system will filter. With this is mine, the team has collaborated in defining these different things and has made them into various categories which will give an insight to these filtrations systems.

First category: Filtration Methods

Diagram

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Vacuum Filtration

First and foremost, the primary purpose of this method of filtration device is to distinguish solids from liquids. The key benefit of this method of filtration is that it incorporates negative pressure at the filtrate outlet. There are two distinct types of filtering; sporadic filtration, which is ideal for thin solutions, and constantly working filtration, which is optimal for treating viscous impure powders.

A mechanically pressed filter has been produced in order to produce a filter residue with a low moisture content. A basic filter press is made by separating the container into upper and lower chambers using a filter medium. The suspension is applied to the upper chamber and reaches the lower chamber under strain through the filter medium, forming a filtrate, with the rigid particles stuck on the filter medium's surface forming a filter residue (or filter cake).

The filter residue layer on the surface region of the filter medium steadily thickens during the filtration process, raising the resistance of the material flowing through the filter residue layer and reducing the filtration speed. Filtration is halted, the filter residue is discarded, and the filter medium is regenerated to complete a filtration cycle when the filter chamber is loaded with filter residue, or the filtration speed is too slow.

To conquer the resistance, the liquid must flow between the filter cake layer and the filter medium, which requires a pressure gap on both sides of the filter medium, which is the guiding force for filtration. While raising the pressure differential will speed up filtration, the particles deformed after being pressed are more likely to block the pores of the filter medium when the pressure is strong, resulting in slowed filtration. Slag layer filtration, deep filtration, and sieve filtration are used to filter the suspension. The term "filter residue layer filtration" refers to the formation of the original filter residue layer during the first step of filtration. Following that, the filter residue layer performs a vital function in filtration. Both large and small particles are trapped during this time; deep filtration indicates the filter medium is dense and the suspension includes both large and small particles. There are less stable objects, because the particles are smaller than the filter medium's pores. The solid particles trapped by the filter are larger than the pores of the filter medium, and the inside of the filter medium does not adsorb the solid particles after they have been filtered; the sieve filter is the solid particles trapped by the filter are larger than the pores of the filter medium, and the inside of the filter medium does not adsorb the solid particles after they have been filtered. The coarse impurities in sewage are filtered out using filtration systems such as a tumble filter screen.

The three approaches are often used concurrently or sequentially throughout the actual filtration operation. The filtration speed determines the filter's processing power. The pores of the filtered filter residue layer are reasonably smooth while the solid particles in the suspension are wide and standardized in size, and the filtrate flows through the filter residue layer at a relatively high pace. The usage of a coagulant to aggregate fine particles into larger agglomerates assists in the speeding up of the filtration process. The filter applied in the upper part of the filter medium is applied so that the filtration direction is consistent with the direction of gravity, and the coarse particles are first settled, which can reduce the clogging of the filter medium and the filter residue layer; in the difficult-to-filter suspension ( If the solid particles settle quickly), the filter applied in the upper part of the filter medium is applied so that the filtration direction is consistent with the direction of gravity, and the coarse particles are first settled, which can reduce the clogging of the filter The filtration method can be sped up with these steps.

(The principle of vacuum filtration[Hawach Scientific])

Centrifugal Filtration

Antonin Prandtl is credited with inventing this method of filtration device in 1864, which was used to isolate milk and cream on a wide scale. Later, Swiss physician and biologist Friedrich Miecher exposed him to research labs for the first time. Furthermore, centrifugal separators are propelled by the centrifugation method. Centrifugation separates ions from a solution by using centrifugal energy. This method is usually used to isolate two immiscible liquids in a solution.

An inlet, exhaust, and separator are also used in the centrifugal separator. The combination of liquid and strong, solid and liquid, or gas and solid is poured through the separator's cone-shaped operating apparatus. The separator induces a revolving vortex, which enables solids to be filtered from liquids. The solids that have been removed are deposited at the bottom of the separator and purged. The contaminant and high-density liquid flow out of the separator, while the low-density portion stays inside. Since water is one of the denser substances, it passes outside and is drained into an outlet. Lower density fluids, such as gasoline, will, on the other side, stay at the core of the vortex. The extracted oil can be quickly retrieved from the separator's suction orifice.

(The principle of vacuum filtration. (2018, September 06). Retrieved February 27, 2021, from https://www.vacuumfiltrations.com/the-principle-of-vacuum-filtration/)

Also, centrifugal separators are available in different designs and capacities. Depending on their designs, they are utilized in different ways across various industries. Here are some applications of the filtration system.

· Pre-Filtration: The centrifugal separator helps improve the efficiency of filtration as well as minimize liquid loss when it is used for pre-filtration. This pre-filtration helps users save on expensive water treatment solutions.

· Protecting Heat Exchangers: They help protect heat exchangers effectively against fouling. Centrifugal separators can remove scale and suspended grit easily.

· Protecting Spray Nozzles: Centrifugal separators are also used for protecting spray nozzles and small orifices in various industrial applications. How? These separators help remove solids that clog the nozzles of the spray. This, in turn, helps reduce the wear and tear of the nozzle, as well as avoid its regular replacement.

· Reducing Industrial Waste: As known centrifugal liquid separators are designed to remove solids from a liquid. This becomes advantageous in case of applications, where the disposal costs are high, or where recovery of high solids is mandatory. This also helps improve the life of seals.

(Centrifugal separators [Cannon, D., & Cannon, P.])

Figure 2: Centrifugal Separator Diagram

The disparity in specific gravity between the liquid and the solid being filtered defines the effectiveness of centrifugal separation. If the gap is high, the separation efficiency can boost. The particle size has an effect on separation efficiency. The visibility requirement for most separators is set at 40 microns.

Apart from being used in a number of industrial applications, there are many drawbacks to utilizing this form of filtration device, as well as several applications in which it is used.

· Maintenance Free: The centrifugal separator is largely maintenance-free owing to the absence of moving parts or other components. It is fitted with an automatic purge valve designed to flush the debris and contaminants automatically.

· Minimal or No Downtime: This is another major advantage of centrifugal separator water filters or centrifugal separators used in the industrial process. As the filtration is performed by the spinning of a vortex, there are no real filters involved. This means there will no accumulation of debris in filters, and there will no breakdown due to this accumulation. Also, there will no need to change the filters more often, as in the case of other liquid separators.

· Minimal Liquid Loss: Do you know there is a little liquid loss by purging while using centrifugal separators than other filters! Typically, the users have to bear major liquid loses when cleaning sand media filters or automatic strainers.

· High Efficiency: The efficiency of centrifugal separation is 98% of 40 microns in a single pass. However, for centrifugal separator, this is 44 microns. This stands valid for solids at the gravity of 2.6 and water at 1.0.

· Environmental Processes: A centrifugal separator is used in various environmental processes for industrial and municipal wastewater treatment. It is widely used for separating biomass and animal slurry from water.

· Recycling: Water impurities are one of the main concerns of various recycling plants. These centrifugal separators are used for treatment and recovery processes at recycling plants. They are widely used for recycling service water in various industrial processes.

· Plastic and Chemical Processes: In the chemical industry, water is used in various phases of chemical manufacturing. Various types of byproducts are generated during chemical processes which may get mixed with water, thereby polluting the water stream. The industrial centrifugal filters help avoid contamination of water streams and recover intermediate or end products during the process. Centrifugal separators are also used during plastic manufacturing. They find great applications during PP, HDPE, and PVC polymer production. Similarly, these filters are used in minerals and ores production, pharmaceutical and biotechnology sectors, and during the production of non-fossil fuels, among others.

· Food and Beverage Production: This industry uses a lot of water and also releases byproducts during various production processes. This is where centrifugal separators can help. They are used during the processing and recovery of non-liquid food products, fruit and vegetable juice production, wine and sugar processing, among others.

· Oleo-Chemistry: Several byproducts are generated during the production of oleo-chemistry derivatives. They can be easily filtered using centrifugal separators. These separators are also used for refining edible vegetable oils. However, they are not recommended to use during the refining of olive oil.

· Mineral Fuel and Lubricating Oils: Industrial centrifugal filters are used for purification and conditioning of fuels, purification of lubricating oils, and treatment and recovery of various fuel oils. They are also used for the treatment of slop-oils from lagoons or refineries or bilge water.

· Animal-based Products: The meat and fish processing create lots of useful and non-useful byproducts. The centrifugal separators are used for the treatment of byproducts from meat and fish processing industries.

(Centrifugal separators [Cannon, D., & Cannon, P.])

Gravity Filtration

When it comes to extracting solid impurities from an organic liquid, gravity filtration is the tool of option. A drying agent, an unnecessary side product, or a residual reactant may both be impurities. While gravity filtration may be used to capture solid substance, vacuum filtration is most often used since it is quicker. To remove insoluble impurities from a hot fluid, a filtration technique known as "hot gravity filtration" is used. Fluted filter paper and close attention to the process are needed for hot filtrations in order to maintain the apparatus warm yet protected so that the solvent does not evaporate. In organic chemistry teaching laboratories, hot gravity filtrations are no longer used in standard procedures for studies.

When scraping the solid precipitate to remove the filtrate, the liquid, for further function or examination, a simple filtration under gravity is used. Filter paper, filter funnel, retort stand to set and carry the funnel, and a conical flask to collect the filtrate are the tools used for this filtering technique.

(What is the difference between vacuum filtration and gravity filtration? (2020, January 18). Retrieved February 28, 2021, from https://www.labrotovap.com/what-is-the-difference-between-vacuum-filtration-and-gravity-filtration/ )

Figure 3. Gravity Filtration Diagram

Cold Filtration

The cold filtration process involves using an ice bath to quickly cool down the crystallization solution rather than setting it out to cool down at room temperature. This process creates very small crystals, as opposed to huge crystals, which can be produced by cooling the solution to room temperature.

(Filtration. (2021, January 16). Retrieved February 28, 2021, from https://en.wikipedia.org/wiki/Filtration )

Figure 4. Cold Filtration demonstration

Hot Filtration

The hot filtration method's primary objective is to remove solids from a hot solution. This is achieved to avoid the development of crystals in the filter funnel and any equipment that comes into contact with the solution. As a consequence, the equipment and the solvent used are heated to avoid a sudden drop in temperature, which would cause the solids in the funnel to crystallize and obstruct the filtration method. The usage of a stemless filter funnel is one of the most critical steps in avoiding the creation of crystals in the funnel and maintaining successful hot filtration. Owing to the lack of a stem in the filter funnel, the surface area of interaction between the solution and the stem of the filter funnel reduces, preventing re-crystallization of the solid in the funnel and negatively impacting the filtration mechanism.

(Filtration. (2021, January 16). Retrieved February 28, 2021, from

https://en.wikipedia.org/wiki/Filtration )

Figure 5. Hot Filtration Diagram

Gravel Filtration & Multilayer Filtration

Gravel filtration is a deep-bed filtration process that uses a multi-layer filtration device (filter gravel + filter carbons). Water passes through multiple layers of filter content with increasing fineness in the direction of filtration through multi-layer filtration. Based on the size of the soil, it is agglomerated in the different layers of the filter. Significant volumes of solids may be absorbed by multi-layer filters. Gravel filtration, commonly known as multi-layer filtration, is used in combination with flocculation to filter river water. Filtration is often followed by a sedimentation stage as the first phase step in these situations. Back-flushing is used to disinfect gravel and multi-layer filters on a daily basis.

Furthermore, depth filters (Sutherland, 2011) are porous filtering mediums made up of cellulose fibers and inorganic absorbents that are used in multi-layer filtration. They can maintain pollutants through the thickness as well as on the surface during liquid filtration, unlike surface filtration. In a common medium, these hybrid systems incorporate two distinct separation concepts and technologies. Filtration by particle rejection is accomplished by creating an intricate mesh in which a practical inorganic particle performs selective adsorption. Separation can be increased still further by adding other additives to the network, such as charged polyelectrolytes (Dizge et al., 2011). A cationic polymer that adsorbs the typical negatively charged dissolved pollutants in a far smaller pore size than the normal pore size may be added to the medium. However, most depth filtration studies in the literature have concentrated on membrane separation modeling (Polyakov, 2008, 2009; Sutherland, 2011; Kuhn and Briesen, 2016; Bedrikovetsky et al., 2017; Goldrick et al., 2017); there are few experimental studies optimizing depth style filter activity, especially in terms of membrane structure.

Controlling filter structure/composition and operating mode will tailor filtration efficiency in a variety of ways. Dead-end filtration and cross-flow filtration are two effective types of service, with the flow passing directly through the filter in dead-end and tangential to the filter in cross-flow filtration (Liderfelt and Royce, 2018). These processes may also be regulated using constant pressure or constant flow rate modes. In any case, the non-constant parameter is tracked, and the reported parameters are used to determine the degree of filter fouling or clogging (Iritani et al., 2015; Goldrick et al., 2017). Modifying the composition and configuration of filters may also improve filtration efficiency. Multi-layer layered filters of different pore sizes stacked on top of one another provide an easy way to separate cells or particles in a sequential manner (Saefkow, 1995; Rijn, 1998). Filtration was modeled on a multi-layered membrane system with each layer having different pore sizes stacked on top of one another in a recent analysis by Griffiths et al. (Griffiths et al., 2016). The effectiveness of a multi-layered filter structure was investigated using a model that simulates particle transport and filtration via a multi-layer structure. This model describes the filter and gives recommendations for the number of filter layers, pore size in each layer, and pore interconnectivity between layers.

Filtering bacteria using multi-layered filters to increase bacterial capture has also been documented (Koch, 1984). Through mechanically adding one sheet to another, which includes a bacteria-destroying substance, the researchers hoped to achieve higher bacteria rejection. A nano fiber film was added to the original layer of a fibrous filter in another analysis (Wertz and Guimond, 2014). Filter media with a first layer adhered to it and a nanofiber layer adhered to it had beneficial properties, such as improved dust keeping ability.

Despite the fact that multi-layered filters are commonly used in industry, few studies have systematically quantified their adsorption and filtration mechanisms, and still fewer have characterized the impact of multi-layered structure on depth filter efficiency. We generated multi-layered and single-layered filter systems using the same amount of filter media in this analysis. Depth filter layer processing was modeled after the papermaking method and checked for adsorption and particle rejection. Using an advanced image technique and colloids and surface principles, the adsorption and filtration processes behind the output of single and multi-layered filters were studied in terms of chemical engineering and internal filter structure.

Figure 6. Gravel Filtration & Multilayer Filtration Diagram

Mechanical filtration

In mechanical filtration, untreated water passes through a mesh filter or cartridge that traps suspended particles on the surface or within the filter. Within this type of filtration system, there lays three most used techniques, which are Cartridge sediment filters, Single media filters, and Multimedia filters.

The type of mechanical filtration that will be suitable to your unique situation depends on the amount and size of suspended solids in the water and the rate at which water needs to be filtered. For example, a sand media filter has a faster contaminant removal capacity than other types of filtration devices, but it is not suitable for the removal of smaller particles. In contrast, cartridge sediment filters with fiber or ceramic filter materials are made with a smaller and more uniform pore size and can be more reliable in removing smaller particles, but they are much slower and need more frequent replacement.

Types of cartridge sediment filters

There are two basic types of sediment cartridges, depth-type and pleated-type. Depth-type filters have graded densities with large openings (or porosities) at the outermost surface of the filter, which decrease in size toward the center core. These filters trap particles within the filter material and are usually inexpensive. Pleated-type cartridge filters contain a rigid polypropylene core for support and are made of one of the following materials:

· Pleated paper – These filters are the most economical but are not reusable. They are sensitive to water with low or high pH (less than 6.5 or greater than 8.5). Use them only when the water contains no active bacteria, which may grow on the cellulose portion of the filter. Water testing for pH and total coliform and E. colishould be conducted to assess whether your water is suited for these types of filters.

· Pleated cotton and polyester – These filters are generally considered the most versatile. They combine the filtration ability of cotton with the strength of polyester. As long as the water pH is between 4 and 9, they can be cleaned and reused several times.

· Pleated polyester and polypropylene – These filters are the most expensive but can be repeatedly rinsed and reused. However, since the fibers are smoother than the other filter materials, they are not quite as effective at retaining particles.

Pleated cartridges have a high filtration surface region, allowing for faster filtration. The filter collects particles on its outermost surface, causing a filter cake to form, which improves filtration but delays water movement (or speed of filtration). They can accommodate huge volumes of particulates and turbidity without creating a drastic decrease in water pressure. While they are initially more costly than depth-type cartridges, they are less expensive and last longer in the long term.

Turbidity is a measurement of water's relative purity. When a light is shined into a water sample, it is an expression of the volume of light scattered by the materials present in the water. The turbidity increases as the amount of dispersed light increases. Clay, silt, thinly divided inorganic and organic matter, bacteria, soluble colored organic compounds, and microscopic plants (not recognizable to the naked eye) and other microscopic species all contribute to the turbidity of water.

Figure 7. Mechanical Filtration Process

Water pressure forces water through the media or fiber wraps through the inner cylinder in the sediment filtration phase, where it is then free to pass through the water line. The medium contains toxins and dissolved solids from the stream.

The pore space between media fibers or granules can decide how many particles are kept. These filters come in a number of sizes and meshes, varying from fine to coarse. The average pore size is reported on most filters, and the vendor scores them based on the smallest particle they can trap. A 10-micron (one thousandth of a millimeter) filter, for example, will capture particles with a diameter of 10 microns or greater. When shopping for filters, keep in mind that many are only rated for particles 20 microns in diameter or larger. Clay (less than 2 microns) and certain silt particles (2.0-50 microns) smaller than 20 microns can not be effectively eliminated by filters with this rating. They would, though, capture sand particles varying in size from 50 microns to 2 millimeters.

The cleaner the filter, the more contaminants are trapped, and the filter must be adjusted more often. The filter can quickly clog if the pore size of the filter material is too tiny, or if the content of suspended solids in the untreated water is too high, causing regular replacement. Suspended solids, on the other hand, can move through the system if the pore size is too big.

When a fresh or replacement cartridge is fitted, the water pressure into the filter is at its highest. A filter cake forms when stuck content accumulates in the filter, and may improve its efficiency by aiding in the filtration phase. Water flow, on the other hand, would eventually decline as trapped fluid accumulates. The filter cartridge can be washed or removed until the water flow becomes too sluggish to use.

Single Filters and Multimedia Filters

Media filters consist of a tank, a single filter medium, multiple filter layers, a support system, and an underdrain. The bed depth of the filter medium is usually 24 to 36 inches and is comprised of silica sand, aluminum silicate, and/or crushed anthracite (a hard, compact variety of mineral coal). Usually a gravel support system prevents the medium from being washed out of the device. Media filters can be cleaned by backflushing and reused. Filters are rated by the smallest particle sizes they remove. With a same sized tank, multimedia filters have a greater filtering capacity than a single-media filters. Generally, multimedia filters also operate at a higher flow rate and require less frequent maintenance than single-media filters.

Here are some examples of how this filter is used and, one thing to take notice is that media filters are point-of-entry (POE) devices that treat water at its entry point into the home. Some common uses of media filters are:

· Media filters remove particles that cause turbidity (cloudiness of water). These filters can also be part of iron, manganese, and hydrogen sulfide removal after they have been oxidized into solid particles via aeration, chlorination, ozonation, or greensand filtration. See UGA Extension Bulletin 939, Circular 858-11, and Circular 858-15 for explanations of these treatment systems.

· A media filter can be used as a prefilter when suspended solids in the source water could reduce the effectiveness or service life of another primary treatment device like ultraviolet light or chlorination units used to disinfect water. If suspended solids are not removed prior to the UV device or chlorination unit, the solids may shield microorganisms from the killing action of light or chlorine and result in unsatisfactory treatment performance. See UGA Extension Bulletin 1487, “Household Water Treatment: Disinfection Methods and Devices.”

· Prevention of sediment build-up in washing machines, dishwashers and hot water heaters

Furthermore, a single media filter operates by enabling untreated water to reach the filter tank under pressure from the top and percolate through the medium, trapping any suspended solids. At a significantly decreased strain, treated water escapes the system from the bottom of the medium. Suspended solids settle on the media surface, creating a filter cake, which helps in the filtering of fine particles but decreases water movement over time. The multimedia filter operates in a similar manner, only that the various levels of filter media are organized in order, with the coarsest content at the top and the finest at the bottom. Bituminous coal/plastic beads and anthracite coal/sand/garnet are two instances of sequential media layering from the top.

At the bottom of the media bed is a media support structure (usually gravel) and an underdrain. The media does not wash through the underdrain because of the gravel support. Under heat, water reaches the top of the tank and passes across the media layers. Suspended solids are suspended by lower layers after passing through the top layer. Multimedia filters, in comparison to single-media filters that capture suspended particles at the top of the media column, trap particles throughout the depth of the web. Multimedia filters, on the other hand, need less regular maintenance than single-media filters. The interparticle pore space, which specifies the size of suspended solid particles in untreated water that will be filtered out, is defined by the particle size in the different media layers.

Granular Media filtration

Granular Media Filtration (GMF) is the process of removing suspended or colloidal particles. For example, to remove the suspended solids remaining after precipitation. By removing particles of various sizes (from coarse sediment down to 10.0μm), it can reduce turbidity and improve clarity. Filtration can protect the IX resin bed and RO/NF membrane elements from particle contamination. Media filters have different size exclusion levels, from 10 to 100 μm, depending on the size of the particles to be removed. Generally, when the water sludge density index is about 5, suspended and colloidal particles can be removed by GMF, dead-angle MF and crossflow MF. For high-concentration colloidal substances, coagulation and flocculation are required before media filtration.

The granular multimedia filter has a layered bed of anthracite (0.8-1.2 mm in size), sand (0.5-0.8 mm), garnet (0.4-0.6 mm) and magnetite (0.3-0.4 mm) or other materials, such as As shown in Figure 2.4. The top layer of the bed is composed of the lightest and coarsest graded material, such as anthracite, while the heaviest, finest material, such as garnet or magnetite, is the bottom layer. The middle layer is silica sand. The specific gravity of anthracite is one-half of silica sand. The typical bed depth is 1 m. The principle is "deep filtration"-larger particles are removed in the top layer, and smaller particles are removed deeper in the filter medium, that is, the entire bed acts as a filter, instead of the top few centimeters.

Figure 8 : Granular filter

During use, water usually flows from the top to the bottom under pressure. The typical service surface flow rate (velocity/cross-sectional area of bed) for single media gravity and pressure filters is 7–12 m/h, multimedia media gravity and pressure filters are 14–20 m/h, and 12–24 m/h is used for Upstream filter. The operation of the filter must avoid channeling and "leakage" of suspended solids. Otherwise, the reverse osmosis membrane will be soiled. There is a water level above the bed (freeboard is 50-100%) to expand the bed during backwashing. Since suspended solids will collect on the medium, regular cleaning (backwashing) is required. The repelled particles form a layer on the surface of the media and help to block the pores in the filter media, resulting in an increase in pressure drop (ΔP). Generally, when ΔP reaches 1 bar, the filter will be backwashed. During the backwashing process, the water flows in the opposite direction. It enters the bed from the bottom and flows upward. This fluidizes the bed and, together with the countercurrent flow, removes the sludge and takes away the waste material. Depending on the temperature, the typical backwash flow rate is 24–36 m/h, which is sufficient to expand the media bed by at least 50%. The backwash cycle lasts 10-15 minutes, followed by a rinsing cycle in which water is circulated in the downward flow direction for 5-10 minutes.

Second Category: Filter Types

Filter paper

For good reasons, wire mesh and wire mesh industrial filtration are commonly used in commercial and industrial/OEM applications. In some industrial filtration applications, the goal is to protect downstream components from particulate matter. In other cases, a wire mesh filter can be used to separate or screen one substance from another.

Whether your specific industrial filtration application needs to remove harmful contaminants from fluids or air, protect expensive process equipment, or just separate one material from another. Bag dust collectors, cartridge dust collectors and dust filters are usually made of synthetic media. Many filtration companies can create your precise size filter and replace stainless steel wire mesh or wire mesh media to achieve better fluidity and more efficient machine functions.

The flow rate in the sediment filter and the separator has a large overlap between the sizes. For example, a 1" filter housing has a flow rate of 1-25 GPM, while a 1-1/2" filter housing has a flow rate of 10-50 GPM. If your flow rate is within this range, it is best to choose a smaller size to ensure that the centrifugal force is sufficient to separate the sand from the water. This means that if you want a flow rate of 20 GPM, a 1-inch filter housing will be more effective.

There are two different styles of elements, filters and separators. They all work in the same way; the difference is that the separator allows more sediment to accumulate before it needs to be removed. Our "Understanding Sediment Filters and Separators" blog describes the differences in more detail. 1.5 and 2 elements Depending on the size of the housing, the appearance of the filter may vary. For the 1-inch housing, the filter between the filter and the separator looks the same, while for the 1-1/2-inch and 2-inch housings, the filter has a shorter screening area and keeps the filter part at the valve stem at the top, which provides space for the accumulation of sediment at the bottom. The image shows a filter element on the left and a separator element on the right for a 1-1/2" or 2" housing.

Figure 9: Filter and Seperator element

Mesh Material

Mesh fabric is a barrier material made of connected strands. These strands can be made of fiber, metal or any flexible material. The connection threads of the grid produce a net-like network with many different uses and applications. Mesh fabrics can be highly durable, strong and flexible. They are known and are usually used in the case of liquids, air and fine particles that require permeability.

The history of mesh fabrics can be traced back to 1888, when a British textile factory owner introduced the concept of a clean, breathable material that can withstand temperature changes into the product. Since the yarn is knitted or woven together and has an open space between the yarn strands, it is a superior material for clothing and fashion, and has been used in clothing, wraps, gloves and scarves in the last century in the final product. When wet or dry, the material has great adhesion (this only means that the dye will not wipe off). The mesh is also easy to sew.

There are two main types of mesh materials, polyester and stainless steel. The polyester mesh is made of non-corrosive materials and has UV stability/weather resistance. The stainless-steel mesh is made of 316 stainless steel, which is non-corrosive and durable. Stainless steel will better absorb sharp deposits and particles because they will not tear the material. In the past, polyester was a more economical choice, but this changed them and made it a very economical choice. As the fibers are woven together, they create a very flexible, net-type finish that has a tremendous range of end-uses. It can be used in so many industries, including: the food industry; wastewater industry (separating waste and sludge from water); hygiene and sanitary industry; pharmaceutical industry; the medical industry (supporting internal organs and tissues); paper industry; and the transportation industry.

Mesh Material Sizes

Mesh fabrics can come in many different sizes and are clearly numbered for understanding. Choosing the required mesh size depends on what needs to be removed from the water. When talking about filtering, there are different terms that define the size of the items to be removed. The equivalent table below shows a comparison between different terms. The equivalence diagram opening is the size of the space between the water and the material through which the particles can pass. The number of openings in a square inch screen is called the mesh size. The micron level is the distance between filter media. A micron is one-millionth of a meter or one twenty-five thousandth of an inch. This is described in more detail in "Water Filter-The Basis of Micron Grade". When using a sediment filter or separator as a pre-filter for other water filtration products, make sure that the mesh size is equal to the larger micron level.

Figure 10: Equivalence Diagram

For example, a 4-mesh screen means that there are 4 "squares" on a linear inch of the screen. A 100-mesh screen only means that there are 100 openings on a linear inch, and so on. To determine the grid size, count the number of rows of grid squares in one inch of linear space measured. This will provide the grid size, which is the number of openings per inch. Sometimes, the grid size may be refined to 18×16, which is defined as 18 holes per 1 inch square and 16 rows of openings down. However, the particle size of a mesh fabric is an indication of the size of the material that can penetrate and pass through the mesh. For example, the particles contained in a 6-mesh powder can pass through a 6-mesh sieve.

Third Category: Coolant Types

Coolants are an instrumental section of machining, together with grinding, milling, and turning. They assist lengthening the devices lifestyles and grant a better finish to machined components. Understanding the function and sorts of coolant will assist you to pick out a coolant that is the proper for your machine and operation. By exactly keeping the awareness degrees of your coolant, you lengthen now not solely the lifestyles of the coolant however additionally your equipment and machine.

These following points are the things that the coolant helps provide.

· Reducing and removing the heat build-up in the cutting zone and workpiece

· Provides lubrication to reduce friction between the tool and removal of the chips

· Flushes away chips and small abrasive particles from the work area

· Protects against corrosion

According to, https://www.firetrace.com/fire-protection-blog/importance-of-coolants

Furthermore, coolants are classified into four groups and come in a number of formulations. Coolant should be chosen based on its overall efficiency, which again should be tailored to your machining application and materials. Here are the following groups.

· Soluble Oils:

The most widely used of all water-soluble cutting fluids, and an excellent option for general machining. The disadvantage is that if the coolant sump is not properly maintained, they are susceptible to fungus and bacteria microbiological growth.

· Synthetic Fluids:

Since they contain no mineral oil and refuse tramp oil, these fluids are the cleanest of all cutting fluids. They do, however, have the least amount of lubrication.

· Semi-synthetic Fluids:

They are thought to be the best of both worlds because they contain less oil than emulsion-based fluids, have a less pungent odor, and have many of the same lubricating properties. As a result, they can be used for a wider variety of machining.

· Straight Oils:

These are non-water miscible and contain lubricants such as vegetable oils, fats, and esters, as well as a mineral or petroleum oil foundation. They provide the best lubrication but have the worst cooling properties.

How Machine Coolant Systems Work

The coolant mixture floods the work area during the machining process. Chips and particles are also washed away from the work area during this operation. A sump at the bottom of the unit absorbs the coolant. The coolant is recirculated to the work area after being pumped out of the sump.

Coolant systems, both central and single unit, must be tracked, maintained, and modified. Small coolant systems, on the other hand, prefer to use less efficient filtration and oil separation equipment than central systems. Smaller structures are often more vulnerable to sudden changes in concretion levels and greater fluctuations. As a result, small-system coolants must be more resistant to contamination from metal shavings, tramp oils, and other materials. Not only does coolant form play a role in extending coolant life, but proper coolant management is even more important.

Coolant Concentration

Several issues will arise if proper coolant concentration levels are not maintained. Low concentration is the most common issue. If the coolant concentration falls below the minimum ratio set by the machine coolant supplier, there is a chance of:

· Machine and workpiece corrosion

· Reduction in tool life

· Bacterial growth

On the other hand, if the coolant concentration is too high, it causes:

· Lesser heat transfer

· Foaming

· Reduced lubrication

· Wasted concentrate

· Formation of residue that shortens tool life

· Staining of machine and machined parts

· Toxicity (skin irritation)

The coolant should be tested at the start of each day to ensure that it is at an appropriate concentration level. Hand refractometers are an excellent way to keep track of cutting and grinding fluid concentrations on a regular basis. Evaporation, splashing, misting, and drag out can cause machine coolant concentrations to fluctuate by 5% to 20% per day. Keeping a daily log of concentration levels for each unit allows you to see how the device works and how much concentration levels fluctuate from day to day.

So again, you will prolong the life of the coolant, the equipment, and the machine by choosing the correct coolant for the type of machine and the metals being machined, as well as preserving the concentration levels.

Fourth Category: Control Systems

Energy efficiency in industry is becoming increasingly important as energy prices rise and the value of climate security grows. According to research conducted by Robert Bosch GmbH, the coolant consumes on average 50% of the electrical energy used in traditional metal cutting applications. As a result, the focus of this study is on lowering the energy consumption of the coolant supply system.

Cooling, lubricating, flushing, and transporting are the primary functions of the coolant. In a circulatory system, the coolant is used and processed. The following functional units can be found in this circuit: supply, return, washing, and cooling (Figure 11). After usage in the machine tool, the contaminated coolant is returned to the cleaning device. In a filter system, the pollution is isolated from the coolant, restoring the necessary fluid cleanness rating. In addition, heat exchangers in a cooling unit keep the coolant temperature stable. There are two types of circulation systems: centralized and decentralized. Centralized systems are commonly favored because they are more cost effective than decentralized systems.

Figure 11. Functional units of a coolant supply system

Various steps to improve the energy efficiency of the coolant supply system have been developed in recent years. A previous study conducted at Robert Bosch GmbH aimed to find additional energy-saving potentials in state-of-the-art coolant facilities. As a result, the energy efficiency of a number of centralized coolant supply systems was assessed. Pumps are responsible for the majority of the energy used in the coolant system. Until now, the primary focus in facility planning and service has been on low acquisition costs and high plant availability, with energy efficiency being overlooked. As a result, simple pump solutions, such as bypass-control pumps, are often used in the design of pumps. These straightforward solutions all have one thing in common: the pumps run at a constant pace and are unable to adjust to changing demand. As a result of the availability of different machine tools and ongoing production changes, the coolant demand in the centralized supply system varies, resulting in low energy efficiency. As a result, demand-based pump control, such as variable speed or level control, is appropriate in the supply system and has become standard in most functional units. According to the findings, there is still a significant amount of energy savings potential in most forms of filter systems with pressure filters. The filter pumps are operated at a constant rpm, and the filter system operates at a high power level indefinitely, regardless of the need for cleaning. Due to the operating mechanism of the filters, a pump control is not easily enforced. This paper uses the example of precoat filter systems to evaluate the energy-saving potential and to present a framework for demand-based control. Precoat filters are widely used in fine machining processes to clean the coolant.

Evaluation of the Energy Efficiency

The criteria for high plant availability and low acquisition costs were met due to the easy operating mode and relatively low plant complexity. The plants, on the other hand, are run inefficiently in terms of energy efficiency. The filter system runs continuously, with all filters operating independently of the amount of coolant needed. Each filter's filter pump operates at a constant speed. As a result, the minimum flow rate must be calculated based on the overall coolant demand needed in the manufacturing process. However, the average demand for coolant in manufacturing is much lower than the maximum demand. Even with maximum filter pollution, the pump's throttle is balanced such that the minimum flow rate is retained (see Figure 12). Because of the pump's characteristic, a lower filter pollution results in a higher flow rate than required. Furthermore, the throttle's pressure loss increases quadratically with the flow rate. As a consequence of the high flow rate, there is a high demand for pump pressure. The inefficient operation is caused by both the excessive flow rate and the excessive pump pressure. Furthermore, up to 80% of the pump's output is dissipated as heat into the coolant. As a result of the excessive heat input from the inefficient pump operation, more cooling power is required to maintain the coolant temperature.

Figure 12. Pump operation with constant speed

Concept of a Demand Based Operation

The basic strategy is to adjust the cleaning output depending on the coolant demand in the manufacturing process, with a follow-up monitor. The procedure is depicted in (Figure 13.) It is made up of two parts: the follow-up control and the filter resistance determination process.

Figure 13. Approach for a demand-based operation

Follow-up control

The flow rate in the filter system's cleaning loop is continuously adjusted with a follow-up control dependent on the actual coolant demand in output. A frequency converter adjusts the throughput of each filter using speed-controlled filter pumps. As a result, the pump speed and, as a result, the pump output are continuously adjusted to the appropriate flow rate and pump pressure (Figure 14).

It should be noted that in filter systems with multiple active filters, it is also possible to switch off a filter when the coolant demand is low. However, since the flow keeps the filter cake on the filter components, the filter can only be removed by backflushing. As a result, the cost of a new precoating filter aid must be weighed. The key opportunity to achieve an energy and resource efficient operation is to continuously adapt the flow through each filter.

Filter Resistance Determination

With the change in filter flow rate, a new filter resistance determination technique is needed to start the cleaning processes. Filter cleaning in existing facilities occurs after hitting a given cleaning intensity. This is possible because there is a clear interaction between the filter pressure and the filter resistance while the pump speed is constant (operation point curve in Figure 12). For the same filter resistance, the flow rate, and thus the flow-dependent filter pressure, varies as the pump speed changes (operation field in Figure 14). With a lower flow rate, the filter pressure drops, and the cleaning process isn't activated at the right time. As a result, the filter pressure can no longer be used as a criterion for filter cleaning.

Figure 14. Pump operation with variable speed control

Modernizations of existing filter systems are more popular than the construction of new facilities, since centralized filter systems are part of the service area and have been in use for more than 20 years. As a result, a retrofit solution based on the proposed method for existing filter systems is critical. To calculate the payback duration of a retrofit, the energy savings must be analyzed. So, in the following section, we'll go over how to model the filter unit, as simulations are needed to assess the energy-saving potential of various options as well as the control behavior. After that, the follow-up control's comprehensive architecture is presented and tested in a simulation scenario.

COMPETITIVE PRODUCTS

Industrial filter systems are widely used by industries and companies in order to allow for industrial operations to flow smoothly and be more efficient. There are various types of filter systems as to which are classified and categorized based on the industries in which the filter system is applied, the process and method of filtration, and the material of the filters. In addition, many filter systems are customized to meet the needs of the user based on the machinery in which the filter system is being made for. As mentioned, there is an unlimited number of manufacturers and companies that are known for their filter systems. However, only four companies that produce filter systems have been taken into consideration for comparison since they are the closest competitors to the Resy Filter Systems. The competitive products are defined and listed below. There are more competitors but only the following would be used for comparison, the rest can be found in the Appendix of competitors.

Examples of Competitive Products

Shelco Filters- https://shelco.com/products/shelco-industrial-products/

Tekleen filters for industry and Irrigation- https://www.tekleen.com

Forsta filters for industrial, irrigation and municipal applications- https://www.forstafilters.com

Compacto Compact Band filter- https://www.u-techindia.com/product/compact-band-filter/

Shelco Filters

Shelco Filters is one of the many leading industrial filter manufacturers in the United States since 1973. They design high-quality filters to improve performance at a lower cost. Shelter Filter Cartiidges are applied in various high-purity applications such as in petrochemicals, photographic solutions, pharmaceuticals, cosmetics, and many others. Additionally, Shelco range of industrial filter cartridges are customized to meet the needs of the customer by the wide range of cartridges such as stainless steel and carbon block cartridges. In terms of customization, Shelco works with customers to ensure that the right designed filter cartridge material is used as well as offering the different design options ranging from duplexing and multiple fittings.

Figure 15: Shelter Filter Cartridges

One of the most common filter cartridges manufactured by Shelco is the Microsentry SS Series- Stainless Steel Filter Cartridge. This type of filter cartridge is designed for extreme high temperature applications greater than 500 degrees Fahrenheit and differential pressures up to 60 PSID. In this way, the filter cartridge is either made up of 304L or 316L stainless steel filter media that is used to provide maximum strength. Based on the design specifications, the filter cartridge can be cylindrical or pressed filter configurations in order to offer more lasting results as well as allow for a greater dirt holding capacity.

Tekleen Filters for Industry and Irrigation

Tekleen water filters is the industry’s highest quality automatic, self-cleaning water filters and strainers. These filters are designed for industrial water filters and irrigation filters. Tekleen Automatic filters has manufactured over 25,000 filters worldwide and providing filters to over 500 companies. Tekleen water filters are offered for various applications such HVAC, petrochemical, sea water filtration, power generation, and even oil production.

Figure 16: Tekleen Water Filters

Tekleen water filters are applied in metal processing. The way these filters' function is by circulating the water through hot wells, cold wells, and cooling towers to cool the jacket molds and metal products. While the operations circulate the water, the dirt particles begin to enter the system while reducing the heat exchangers function as well as clog the spray nozzles. This affects the consistency of the metal and the finished product. However, the finished product may experience many complications such as metal spotting or break-out. Tekleen works to self-clean the water filters reducing such complications that may be experienced while metal processing. These self-cleaning water filters operate on pressure and are very compact in size making it easier to install.

Forsta Filters for Industrial, Irrigation and Municipal Applications

Forsta Filters are automatic self-cleaning water filters that are based on producing less wastewater while also being more cost effective. These filters are also designed to function on their own without causing any disruptions to the rest of the system during the cleaning cycle. In addition, Forsta filters are low maintenance and provide a high efficiency. These filters are applied to various industries such as industrial and irrigation. Based on the industry and application, these filters are customized to specifically meet the need of the consumer. In this way, these filters range in sizes, orientations, and degrees of filtrations all in order to accommodate to the application.

Furthermore, Forsta self-cleaning filters are used to remove particles from the different water sources. Such particles include but are not limited to pollen, dust, metal shavings, pipe scale, marine organisms, and fibers. These filters can be applied to different water sources such as in a reservoir or in wastewater.

Figure 17: Forsta Filters

Compact Band Filter

Compact Band Filters are manufactured and designed by U-Tech. These types of filters are utilized in contaminated coolants that are part of Computerized Numerical Control (CNC) machines. U-Tech Compact Band Filters are designed to offer better filtration and efficiency in comparison to other types of filters. The way that these filters function is based on reducing the amount of filter paper used as well as a decrease in the motor power consumption. That is why this company states and offers a very high degree of reliability of their product and guarantees that the Compact Band Filter will reduce the amount of paper filter and motor power.

The Compact Band Filter has many specified features that allow it to be distinct and more efficient compared to other filters. This filter is very compact in the way that it will occupy less space meaning that it only makes up of one third of conventional paper band filter. As mentioned before, the design of the filter allows for less consumption of paper allowing for paper to last much longer. In this way, the paper filters wouldn’t have to be changed constantly due to the paper lasting much longer than usual filters. This also saves up on having to buy so many paper filters for the machine. In addition, the Compact Band Filter can be used to filter coolant and oil with ferrous and non-ferrous metal and non-metals. Most filters do not function or are not as efficient when it comes to filtering metal shaving or dust. This type of filter does in fact ensure that the surface in which is being filter is left with no residue of any kind leaving a clean and smooth surface. One of the most important features of this filter is that is made up of microfiber and paper filters that come in various sizes in order to meet the needs of the consumer.

Figure 18: Compact Band Filter

All in all, the competitive products that were taken into comparison are shown to have similar and distinct qualities when compared to the Resy Filter System. Most of the competitive product's function in filtering a system by removing certain particles leaving a smooth and clean surface. It was noted that out of the four competitive products, most of them offer customization for the user. What this means is that users are able to request how they prefer or would like their product to be. This is mainly based on the fact that most filters have to be redesigned to fit in certain machinery. These are similar qualities seen in the Resy Filter System which why these products have been selected as competitive products to compare and note that the Resy Filter System is the better option when compared to these products.

Float level sensor

Water level sensors detect the presence of a liquid in a variety of ways and use the information to denote its level. For most of us, the “float” style sensor is the first that comes to mind. A good example is the float valve in a toilet tank. In the case of the toilet, a float connected to a lever manually opens a valve to start the flow of water as the tank empties, then closes it until the appropriate volume is reached for the next flush. While direct mechanical control is an alternative, in industrial applications, a small float's movement is commonly used to trigger a switch that sends an electrical signal to an indicator or a solenoid valve to control liquid flow. Float switches are the name for these machines.

Figure 19: Lever Float Switch

Float switches are simple, cost-effective, and suitable for a wide variety of applications. They are not susceptible to the conductivity, temperature, or precise gravity of the liquid they are detecting, unlike certain other types of liquid level sensors, and can be constructed from a range of materials to be compliant with most liquids. They are especially "user friendly" since they are quick to grasp, troubleshoot, and replace. The most popular instrument for detecting liquid level is the float valve.

They are not, though, the only solution to all liquid level sensing problems. Float switches are susceptible to wear and a range of mechanical failure modes when they have moving components. When used for plain water, for example, a well-designed float valve can be dependable. However, if the water contains chemicals that may cause a residue on the sensor's working components over time, the sensor's durability is called into question. They have the opportunity to get “stuck.” This is particularly problematic when a float valve that detects a high level is constantly wet and dry, causing deposits to accumulate and solidify, forming a crusty residue. Contamination of particles is also a problem. Chips and even clumps of magnetic particles may be drawn to the magnets and block the reed switch's magnetic activation. The magnetic switch is often replaced by a different kind of switch that detects the angle of the float by using mercury to bridge contacts in a sealed tube when a certain angle is reached. However, making reliable communication to the shifting switch housed in the float, which would, of course, travel up and down, is an issue with this method. Because of their sensitivity to mechanical injury, it is recommended that float style level sensors be covered with a small cage or baffle.

A sealed housing containing an angle sensitive switch, similar to the mercury switch mentioned above, is one version of the float switch. The sensor is tethered in the vessel in this situation so that it floats on its side on the liquid surface before the critical liquid level is reached. When this occurs, the tether pulls the sensor to an upright position, which triggers the switch. This kind of float turn is commonly used in liquid storage tanks.

Microcontroller

A microcontroller (MCU for microcontroller unit) is a miniature device built on a single MOS integrated circuit (IC) chip. A microcontroller is a computer that includes one or more CPUs (processor cores), memory, and programmable input/output peripherals. A limited amount of RAM, as well as program memory in the form of ferroelectric RAM, NOR flash, or OTP ROM, is often used on chip. Microcontrollers, in comparison to the microprocessors used in personal computers and other general-purpose devices, are designed for embedded applications and comprise of a variety of distinct chips.

A microcontroller is like, but less complex than, a device on a chip in modern terms (SoC). A microcontroller may be one of the components of a SoC, but it is typically paired with specialized peripherals such as a graphics processing unit (GPU), a Wi-Fi board, or one or more coprocessors.

Microcontrollers are used in products and applications that are remotely controlled, such as car engine control systems, implantable medical devices, remote controls, office machinery, appliances, power tools, toys, and other embedded systems. Microcontrollers make it cost-effective to remotely monitor many more machines and processes by reducing the size and cost of a design that uses a separate microprocessor, memory, and input/output devices. Mixed signal microcontrollers are widely used to monitor non-digital electronic devices by combining analog components. Microcontrollers are a cost-effective and widely used way of collecting data, detecting, and actuating the physical world as edge devices in the internet of things.

For low power consumption, certain microcontrollers use four-bit words and run at frequencies as low as 4 kHz (single-digit milliwatts or microwatts). They can maintain functionality when waiting for a case, such as a button press or other interrupt; power consumption while sleeping (CPU clock and most peripherals off) can be as low as nanowatts, making many of them ideally suited for long-term battery applications. Other microcontrollers can be used in performance-critical applications, requiring higher clock speeds and power usage than a digital signal processor (DSP).

Figure 20: Arduino Microcontroller

In addition, Fig.## above which is an Arduino is an open-source tool that can be used to create electronic projects, which will be considering using in the SD1 project. Furthermore, Arduino is made up of a physical programmable circuit board (also known as a microcontroller) and software, known as an IDE (Integrated Development Environment), that runs on your device and is used to write and upload computer code to the physical board.

Vibrational Analysis

Reactive maintenance (repairing a defect as it occurs), which is gradually being phased out due to its high costs, and proactive maintenance are two common maintenance techniques in industry today (based on physical inspections at scheduled intervals of time). Predictive maintenance is one of the most important fields of study for industrial motors, as well as aircraft, automotive, and marine vehicles, since it reduces total running costs significantly. It's founded on the fact that a mechanical component failure is normally followed by a time of gradual and crescent regression of action and efficiency. These incipient defects may be detected, and measures taken before they cause significant problems or harm to other sections of the equipment if enough on-line tracking is used. Monitoring of security-relevant components and signals is the state of the art and is mandated by qualification requirements in the case of mechanical components of a windmill. The use of a fault detection system in this setting is critical because it has a number of potential benefits, including the prevention of premature breakdown, lower maintenance costs by avoiding the replacement of intact parts during preventive maintenance, remote diagnosis (which is critical because windmills are typically located in remote locations), and prognosis and ada. Vibration control is used in the case of spinning devices, such as the mechanical sections of windmills (bearings, gearboxes, and so on), and fault detection systems analyze spectral analysis results, such as FFT, Cep-strum, envelope curve analysis, and so on, to produce diagnosis and even estimates of the piece's remaining lifespan. The theory behind this is that noises found in all parts of a mechanical system will detect almost any flaw. The vibration analysis is based on the changes that occur in a machine's vibrational behavior when a latent defect is discovered in one of its components. Predictive maintenance of windmills is currently performed manually or semi-automatically by trained professionals, rendering it a high-cost operation. For automated diagnosis and prognosis, many models have been used, several of which employ Artificial Intelligence techniques. There are very few articles published in the field of prognosis. The on-line SBLLM (Sensitivity-Based Linear Learning Method), a prognostic model based on a supervised feedforward on-line learn-ing algorithm for two-layer feedforward neural networks based on sensitivity analysis, is presented in this article. The algorithm provides a compelling combination of speed, accuracy, and simplicity, making it ideal for real-time prediction.

USER RESEARCH

Filtration technology has advanced throughout the years. There are various types of filtering processes as well as the type of filter paper or filter material that is used based on the specifications of the substances used. In this way, there are questions that could be asked to potential customers to fully understand their specifications and expectations when it comes to the filtering technology. For instance, there are various types of filters that are used for different types of materials such as those used to filter a substance that contains metal shavings or even dust. Also, the type of machine that the customer uses is very important since the filters must be designed to fit in the specified machinery. Most manufactures do provide filter customizations to meet the needs of the consumer.

Question that would be asked to potential customers.

1. What type of filtering process is your company looking for? Ex. Centrifugation, Paper band filters, etc. And how big of a scale is the operation you have (Machine wise)?

2. What type of metal cutting machinery do you have?

3. What type of appropriate coolant filtering process does your machine need to be in safe operating conditions?

4. How much space, are you willing to make/or have for the filtering machine?

Figure 21: Stakeholder map

It highly important to understand who the user is and how they may affect other users. Figure 15 illustrates potential users for filter systems for industrial machining fluids in a stakeholder map. As it is shown, the user of the filter system is narrowed down to a machinist technician since they are the ones who understand and utilize the filtering system machine. Most companies have a designated person who will utilize the machinery which is known as the machinist technician. In addition, there are also people who oversee keeping the machine clean and safe to use which can also be known as maintenance. Furthermore, the filter system machine is in the hands of the manufacturers. These manufacturers are responsible in producing the filtering system machine and distributing it to other companies or customers that have purchased the product. There will be existing companies as well as new companies that may want to purchase the product. In addition, there are various industries that use filtering technology. For this product in particular the industries that use this product are known. These include but are not limited to the wire and cable, tooling machine industry, automotive and supplying industry, and the glass and environmental industry.

Safety is also something take into consideration. There must be supervision and inspection of the filtering systems to ensure that they function properly and are safe to use. There are different organizations such as OSHA that need to approve that the machinery used is safe to use. The Occupational Safety and Health Administration should be taken into consideration in the designing of the product. The product needs to be approved by this organization to ensure that any material being used will be at no harm to the user. For instance, a metal used in the product might cause a reaction if a person is in contact with it leading to a more complicated health issue. If this occurs, the company or manufacturer may be sued and may be found guilty if this issue occurs amongst more users. That it is why it highly important to consider the different materials used in designing of the material and how it may affect the user. In the case that the safety standards are not met due to any factors such as the design, the machinery is not allowed to be used or able to be put in the market. In addition. there are certain standards that are to be followed. While designing the product, it is highly important to note what the standards are, and which ones are to be followed. If the product does not comply with the standards, the product would have to be either redesigned or it wouldn’t be able to be sold or distributed to the user. There are different handbooks that include these standards such as the American Society for Testing and Materials. This is an ‘international standards organization that develops and publishes voluntary consensus technical standards for a wide range of materials, products, systems, and services. In addition, suppliers who comply with these standards are more than likely to offer best quality products to their customers. In order to ensure that these standards are being followed, various testing has to be conducted in order for the product to be ASTM certified.

OSHA

With the Occupational Safety and Health Act of 1970, Congress created the Occupational Safety and Health Administration (OSHA) to ensure safe and healthful working conditions for working men and women by setting and enforcing standards and by providing training, outreach, education and assistance. OSHA is part of the United States Department of Labor. The administrator for OSHA is the Assistant Secretary of Labor for Occupational Safety and Health. OSHA's administrator answers to the Secretary of Labor, who is a member of the cabinet of the President of the United States. https://www.osha.gov/laws-regs/regulations/standardnumber/1910

Figure 22: OSHA Top 10 Standards

Six main types of OSHA violations

1. De Minimis Violations: A de minimis violation is a technical violation of OSHA rules that have no direct impact on health or safety. It is the least serious class of violation, and inspectors do not levy fines or issue OSHA citations for these violations. Inspectors verbally inform employers about de minimis violations and list them on the employer's case inspection file. A ladder with 13 inches between rungs rather than 12 inches is an example of a de minimis violation.

2. Other-than-Serious Violations: A violation of OSHA rules that would not usually cause death or serious injury but that is nevertheless related to job safety or employee health is considered an other-than-serious violation. According to the United States Department of Labor, the maximum penalty for each such violation is $13,494. However, inspectors can choose not to levy a fine, or to reduce the penalty by as much as 95 percent. Inspectors make decisions about penalties based on factors such as the size of the business and the cooperativeness of its owner. Failure to provide copies of safety regulations and failure to post required documentation in work areas are considered other-than-serious OSHA violations.

3. Serious Violations: When an employer knows of or should know of a situation that has a definite chance of causing serious injury or death, but does not remedy it, OSHA issues a serious violation. Inspectors must assess OSHA fines of up to $13,494 for each serious violation, but they can adjust penalties based upon the seriousness of each particular violation, as well as the employer's previous history, the size of the business, and the good faith of the employer. Failure to ensure that employees who carry heavy loads wear steel-toe boots is an example of a serious violation.

4. Willful Violations: The most serious violation category is willful violations, and it is reserved for intentional violations of OSHA rules or situations that show disregard for employee health and safety. According to Health Leaders Media, the minimum penalty for each willful violation is $9,639 and the maximum fine is $134,937. If an employee is killed, the maximum fine is $10,000, six months imprisonment, or both. Occupational Health and Safety Magazine shares that more and more state prosecutors are also pressing criminal charges in these cases. An example of a serious violation might involve a fatal crushing accident because the employer did not implement adequate safety procedures for equipment that had caused prior crushing injuries.

5. Repeated Violation: If an employer is cited for a particular violation, and a subsequent inspection reveals another identical or very similar violation, OSHA inspectors may cite the employer for a repeated violation. The maximum fine for a repeated violation is $134,937. However, if the employer contests the original violation and is awaiting a final OSHA decision, inspectors cannot consider a violation of the same type to be a repeated violation.

6. Failure to Abate Prior Violation: When an employer receives a violation citation, the citation includes a date by which the employer must remedy the situation. If the employer does not do so on or before the specified date, it may be liable for a fine of $13,494 per day from the day after the specified date until it remedies the condition.

https://work.chron.com/types-osha-violations-10693.html

CONCEPTUAL DESIGN

The objective of the Conceptual Design stage is …

FUNCTIONAL DESIGN

Creating a Functional Reasoning allows us to understand what the product needs to do, and not necessarily how.

Table

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Figure 23: Functional Diagram

MORPHOLOGICAL CHART

The Morphological Chart helps us explore the universe of possible solutions for each function in an orderly fashion.

Graphical user interface

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Table 2: MORPHOLOGICAL CHART

CONCEPT VARIANTS AND SELECTION PROCESS

Combining all possible solutions would generate a factorial number of concept variants, we had to be selective to find the best ones.

Timeline

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Table 3: Concept Variants & Selection Process

FINAL CONCEPTS

After the selection process we arrived at the Final Concept.

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Table 4: Final Concept for Vibration Sensor & Aesthetic Design

Back to INDEX.

EMBODIMENT DESIGN

The objective of the Embodiment Design stage is …

STRATEGIES AND PRIORITIES

Starting from our final concept, we identified the necessary analyses and engineering work to realize the concept into a product.

Figure 24: Over all function of the filter machine

TASK 1: CREATE DIAGRAM OF VIBRATION SENSOR

Diagram, schematic

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Figure 25: Diagram of Vibration Sensor with Base excitation model acting as the Filtration Machine

TASK 2: CREATE THE MODEL/PROTOTYPE AND CONFIGURE CODE

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Figure 26a: Rough Sketch of Vibration Sensor on filtration machine Figure 26b: Model of Vibration Sensor

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Figure 27: Arduino code for Vibration Sensor Version 1

TASK 3: CREATE A BLUEPRINT OF THE FILTRATION MACHINE BY TAKING IT APART

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Figure 28(a) on the left and Figure 28(b) on the right

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Figure 28(c) on the left and Figure 28(d) on the right

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Figure 28(e) on the left and Figure 28(f) on the right

Figures 28(a, b, c, d, e, f): Student Made Blueprint of the Filtration Machine

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Figures 29: Filtration Machine Model; from where the blueprints were derived from, Featuring Team members Karla Morales (on the left) and Marissa Sandoval (on the right)

TASK 4: Conduct research on aesthetic designs for the filter machine

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Figures 30: Vinyl wrap for the Filtration Machine

The team researched what form of paint/wrap was both efficient with time, and both easy to apply and remove.

In addition, the team decided on using vinyl wrap because it had all the necessary characteristics the team needed for the application in the filtration machine, compared to other methods seen below in the table.

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Table 5: Methods of aesthetic design

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Figures 31: Example of Vinyl wrap colors for the Filtration Machine

TASK 5: Acquire rough measurementS from the Filtration Machine to create a 3-D prototype model and implement plexiglass with 7in screen

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Figures 32: Actual model next to rough sketch of Filtration Machine with measurements

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Figures 33: Filtration Machine 3-D model prototype for aesthetic views with implementation of plexiglass on top

Figures 34: Sample measurements of plexiglass and 7in screen for Filtration Machine 3-D model prototype

Progression of Embodiment Design stage FALL 2021

STRATEGIES AND PRIORITIES

FMEA

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Table 6: FMEA

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Figure 35: Example of Filtration Machine in Need of Maintenance

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Figure 36: Example of a well maintenance Filtration Machine

QFD

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Table 7: QFD

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TESTING AND VALIDATION

The objective of the Testing and Validation stage is to see the different variations of the sensors tested until we got to their Final Version.

PRELIMINARY TESTING V1T1 (VERSION 1 TEST 1): TESTING VIBRATION SENSOR CODE

This is the testing protocol, the team started by uploading the code to the microcontroller, until indication light on the microcontroller said it was ready. After that the team opened a data plotter on the software to see the reading the sensor is capturing. Then the team began exciting the accelerometer to see if it picked up the excitations that were done to it. Since the vibration sensor did pick up and display the excitations shown below, the decided to test it with a greater excitations force.

We have added a hyperlink below of a small clip

SDI T1 MESH ARDUINO PROTOTYPE

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Figure 37: Test 1, excitation plot

TEST V1T2: TESTING VIBRATION SENSOR WITH A GREATER FORCE

The team decided to test the vibration sensor with something that would give it a larger amplitude of excitation. So, the team decided to use the base sound system from one of our cars which is stronger than most normal cars have. The vibration sensor succeeded in detecting and plotting these excitations as can be seen below. Now in future the team plans to test it on the actual machine.

Arduino Vibration Trial with speakers

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Figure 38: Test 2, excitation plot Figure 39: Portion of Vibration

Sensor DATA (X, Y, Z) axis

V2T1 (VERSION 2 TEST 1) VIBATION SENSOR WITH LED LIGHT AND BUZZER

The team went ahead and took one step further on improving the vibration sensor with the addition of an LED light and a buzzer to set off an alarm with a flashing light to signal when the vibration sensor is getting high excitations and let the user know when the machine requires maintenance.

Development of Vibration Sensor

FINAL VERSION OF VIBRATION SENSOR TESTING

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Figure 40: Final Vibration Sensor Code

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Figure 41: Vibration Sensor Data Recordings, X-axis

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Figure 42: Vibration Sensor Data Recordings, Y-axis

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Figure 43: Vibration Sensor Data Recordings, Z-axis

PRELIMINARY TESTING V1T1 (VERSION 1 TEST 1): TESTING LOAD CELL SENSOR

The team was able to work with a 100kg load cell sensor and did some research on how it works to be able to understand its functionality and get data from the machine. The team successfully developed a code on the Arduino micro controller to help display information from the load cell sensor to display whenever the load sensor is either in tension or compression. This data will also help the user know when the MESH tensioner is either well under tension or in compression.

Development of Load Cell

As one of the methods needed to size the linear actuator, which is finding working capacity of the MESH band. Our team determined that the best solution to finding the load capacity was incorporating a linear load cell between the pneumatic gas spring and base of the machine.

The team is currently working on making the thread cross overs from 6mm threads to 12mm threads in the machine shop. Again, this load cell will show the user the current working capacity while the machine is operating.

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Figure 44a(left): Horizonal Roller example with web tension cells. Figure 44b(right): Filtration Machine roller bearing

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Figure 45a(right): Manual Pneumatic Tensioner for the Filtration Machine with the incorporation of the load cell and cross overs

Figures 45b(left): Computer Aid Design Schematics of Load Cell Cross overs

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Figure 46: Load sensor with DATA recordings

Development of Load cell & Screen

FINAL VERSION OF LOAD CELL TESTING

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Figure 47: Final Load Sensor Code

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Figure 48: Load Sensor Data Recordings

PRELIMINARY TESTING V1T1 (VERSION 1 TEST 1): TESTING SLIDING PLEXIGLASS WINDOW AND LED SCREEN

The team implemented an LED Screen on the filter machine to allow the user to view the information and data generated from the vibration and load sensors. The user is also able to adjust the height of the LED screen by using the housing to make it easier to use. In addition, the plexiglass is to be placed at the front end of the machine. The user will be able to slide the plexiglass upwards to facilitate maintenance and be able to view the filtering process.

Development of Plexiglass Window

Currently the team is working on a solution to mount the plexiglass sturdy enough to the sliding rails.

The team has currently developed these screen supports to hold the plexiglass inside it while being able to attach them to the sliding rails.

The sliding rails will be 3D printed

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Figures 49: Computer Aid Design Schematics of Screen supports

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Figures 50: Plexiglass Window Benchmark with LED Screen

CURRENT FILTRATION MACHINE ASTHETIC DESIGN AND MACHINE FUNCTION

Operation of Filtration Machine

The team has recently been able to wire and turn on the filtration machine but have found that we need to reverse the polarization of the motor.

Once we fix the polarization on the filtration machine, it will allow us to both find the most efficient placement of the vibration sensor and determine what frequencies are made when machine needs maintenance.

Activating MESH Machine

Aesthetic Design

For our aesthetic design we will show our final product with our color palette and electrical and mechanical components incorporated into the machine.

Figure 51: Load sensor with DATA recordings

Final Aesthetic Design

Figure 52: Load sensor with DATA recordings

FUTURE WORK

This section is to inform about future work applications on the filtration machine

Linear Actuator

This linear actuator will replace the current pneumatic gas spring. The replacement of the pneumatic gas spring will help in preventative maintenance.

Methods which will used to size the linear actuator are the following

1) Finding working capacity (load/tension) that is being applied to the MESH belt

2) Travel (Linear Distance, Stroke)

3) Coding (Microcontroller that can handle multiple sensor inputs)

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Figure 53: Linear Actuator

DC MOtor electrical current sensor

Implementing this electrical current sensor will allow the technician to see electrical current loading on the motor while in use.

Figure 54: DC Current Sensor

Microcontroller O.s.

Integrating this operating system will facilitate communications between all inputs such as vibration sensor, load cell, screen display, linear actuators and future input sensors to improve preventative maintenance.

1) Coding (Microcontroller that can handle multiple sensor inputs)

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Figure 55: Raspberry Pi Micro Controller

REFERENCES

1. Forsta Filters. “Automatic Self-Cleaning Water Filters.” Forsta Filters, 5 Aug. 2020, www.forstafilters.com/.

2. “Shelco Industrial Products.” Shelco Filters, shelco.com/products/shelco-industrial-products/.

3. TEKLEEN. “Self-Cleaning, Automatic Water Filters for Industrial and Irrigation Water Filtration.” TEKLEEN Industrial Water Filter and Irrigation Filter - Self-Cleaning Water Filtration - Automatic Filters Inc., 2021, www.tekleen.com/.

4. U-Tech. “Compacto Compact Band Filter.” U-TECH, 2021, www.u-techindia.com/product/compact-band-filter/.

5. Bedard, Risa. “Choosing a Proper Water Mesh Filter Element.” BoshartU - Free Plumbing Blogs, Articles and Education, blog.boshart.com/choosing-a-proper-water-filter-mesh-element.

6. “Mesh Fabric - History and Applications: Canvas ETC .” Canvas ETC, 19 Feb. 2019, www.canvasetc.com/mesh-fabric-history-and-applications/.

7. “Top Industrial Water Filter Companies and Manufacturers in the USA.” Thomasnet® - Product Sourcing and Supplier Discovery Platform - Find North American Manufacturers, Suppliers and Industrial Companies, Thomas, www.thomasnet.com/articles/top-suppliers/industrial-water-filter-manufacturers-suppliers/.

8. Cannon, D., & Cannon, P. (2019, October 16). Centrifugal separators: Working PRINCIPLE, benefits, and APPLICATIONS Discussed. Retrieved February 28, 2021, from https://cannonwater.com/blog/centrifugal-separators-working-principle-and-applications/

9. What is the difference between vacuum filtration and gravity filtration? (2020, January 18). Retrieved February 28, 2021, from https://www.labrotovap.com/what-is-the-difference-between-vacuum-filtration-and-gravity-filtration/

10. HydroGroup®. (n.d.). Sand filter, DEPTH filter, filter GRAVEL, FILTER SAND, jurassic lime, MARBLE, DOLOMITE, river water FILTRATION, well water filtration, Filtrate, Flocculant, Water flushing, air Flushing, MagnoDol, HydroCalcit, hydrogroup, HYDRO-ELEKTRIK, rwt gmbh. Retrieved March 01, 2021, from https://www.hydrogroup.biz/areas-of-use/water-treatment/filtration.html

11. Onur, A., Ng, A., Batchelor, W., & Garnier, G. (2018, September 12). Multi-Layer filters: Adsorption and Filtration mechanisms for Improved separation. Retrieved March 01, 2021, from https://www.ncbi.nlm.nih.gov/pmc/articles/PMC6143674/

12. Saha, U. (2020, October 01). Corrosive or scaling water. Retrieved March 02, 2021, from https://extension.uga.edu/publications/detail.html?number=B1523&title=Household+Water+Treatment%3A+Mechanical+Filtration+Methods+and+Devices

13. Rahäuser R., Klemm P., Verl A., Kircher C. (2013) Increasing the Energy Efficiency in Metal Cutting Manufacturing through a Demand Based Coolant Filtration. In: Nee A., Song B., Ong SK. (eds) Re-engineering Manufacturing for Sustainability. Springer, Singapore. https://doi.org/10.1007/978-981-4451-48-2_38

14. “The History of Water Filtration.” Pelican Water, 9 Sept. 2014, www.pelicanwater.com/blog/history-water-filtration/.

15. The principle of vacuum filtration. (2018, September 06). Retrieved March 20, 2021, from https://www.vacuumfiltrations.com/the-principle-of-vacuum-filtration/

16. Mein, S. (n.d.). The importance of Coolants in machining. Retrieved March 20, 2021, from https://www.firetrace.com/fire-protection-blog/importance-of-coolants

17. Fuchs, J. (2020, February 18). Liquid level sensors - floats. Retrieved March 26, 2021, from https://techblog.ctgclean.com/2020/02/liquid-level-sensors-floats/

18. Microcontroller. (2021, February 10). Retrieved March 26, 2021, from https://en.wikipedia.org/wiki/Microcontroller

19. What is an Arduino? (n.d.). Retrieved March 26, 2021, from https://learn.sparkfun.com/tutorials/what-is-an-arduino/all

20. Plantservices.com. (n.d.). Retrieved March 26, 2021, from https://www.plantservices.com/articles/2006/154/

21. Martínez-Rego D., Fontenla-Romero O., Pérez-Sánchez B., Alonso-Betanzos A. (2010) Fault Prognosis of Mechanical Components Using On-Line Learning Neural Networks. In: Diamantaras K., Duch W., Iliadis L.S. (eds) Artificial Neural Networks – ICANN 2010. ICANN 2010. Lecture Notes in Computer Science, vol 6352. Springer, Berlin, Heidelberg. https://doi.org/10.1007/978-3-642-15819-3_9

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IMPORTANT FILES

This is a summary of important Senior Design files, click on each to open in a different window.

SDI

REVIEWS

MIDTERM

PRESENTATION

FINAL

PRESENTATION

REPORT

SDII

REVIEWS

MIDTERM

PRESENTATION

FINAL

THIS WEBSITE

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