WO2011068467A1

WO2011068467A1 - System and method for filter debris analysis

Info

Publication number: WO2011068467A1
Application number: PCT/SG2009/000465
Authority: WO
Inventors: Surapol Raadnui
Original assignee: The Thailand Research Fund; King Mongkut's University Of Technology North Bangkok; Axis Ip Holding Pte Ltd
Priority date: 2009-12-03
Filing date: 2009-12-03
Publication date: 2011-06-09

Abstract

Various systems and processes for analyzing debris particles from a set of filter elements are disclosed. The process includes introducing a filter element into a particle separator tube. The filter element includes debris, wear, or other particles of different sizes. The particle separator tube includes a number of filter patches, each having a predetermined pore size. The process further includes agitating the particle separator tube using ultrasonic energy for displacing- debris particles from the filter element along a length of the tube. The filter patches impede passage of debris particles of a size larger than their pore size therethrough, thereby separating the debris particles according to their sizes. Various ultrasonic energy sources that are capable of handling multiple particle separator tubes simultaneously are also disclosed. Such ultrasonic energy sources allow multiple particle separator tubes, which can carry one or multiple filter elements, to be processed concurrently.

Description

System and Method for Filter Debris Analysis

Technical Field

The present disclosure generally relates to the separation, collection and analysis of debris carried by filters or filtration devices. More particularly, the present disclosure describes various embodiments of systems for separating and collecting debris of different sizes, including a system having a simple, space-efficient design that is capable of processing multiple filter samples simultaneously, and corresponding debris collection and analysis processes. .

Background

Both wear and wear-induced failure occur even in properly lubricated machine systems and equipment. The ability to track and analyze or estimate wear or potential sources of component failure facilitates the prediction or determination of equipment life expectancy, operational safety or performance ratings, maintenance needs and recommendations, as well as the identification / origination of contamination or abnormal wear in machine systems and equipment. With technological advancement, there is an increased focus on machine systems and equipment reliability, particularly because modern integrated and automated high-speed machine systems and equipment make any interval of down time non-productive and costly. Having an effective wear analysis program is vital to ensure the reliability and availability of such machine systems and equipment, as well as to reduce costs associated with labor, repairs and downtime.

An increasingly important manner of determining the mechanical condition of the equipment, machine system, or machine components is through the analysis of filter debris or particles trapped by filter elements used in the machine systems and equipments. Filter debris particle analyses are particularly useful and are increasingly being applied in a wide range of industries, for example in the power, process, manufacturing, and automotive industries. Machine systems and equipment designers and builders are increasingly using results from filter debris particle analyses as a realistic criterion for improving a diverse range of products including gears, bearing, and turbine components. Presently available filter debris analysis systems have one or more drawbacks such as design complexity, intricate assembly configurations, large unit sizes, time consuming procedures, high operating cost and limited throughput. Therefore, a need exists for a debris collection or analysis system that is substantially simpler, more cost-effective, less time consuming, and capable of improved throughput.

Summary

In one aspect of the disclosure, a process for analyzing debris particles from a set of filter elements includes introducing the set of filter elements into a set of particle separator tubes, each particle separator tube within the set of particle separator tubes having a set of filter patches providing a predetermined pore size; mechanically and / or sonically agitating the set of particle separator tubes (e.g., using ultrasonic energy) for dislodging the debris particles from the set of filter elements; and collecting a portion of the debris particles on the set of filter patches, such that the portion of debris particles collected on a given filter patch has a minimum size larger than the predetermined pore size of the given filter patch.

In another aspect of the disclosure, a system for analyzing debris particles from a set of filter elements includes a set of particle separator tubes, each particle separator tube within the set of particle separator tubes configured to carry at least one filter element; and an ultrasonic energy source for agitating the set of particle separator tubes to dislodge the debris particles from the set of filter elements, such that each of the particle separator tube within the set of particle separator tubes includes at least one filter patch having pores of a predetermined pore size for collecting debris particles having a size larger than the predetermined pore size of the at least one filter patch.

Brief Description of the Drawings

Embodiments of the present disclosure are described herein with reference to the drawings, in which:

FIG. 1 shows a system for collecting and analyzing debris particles from a set of filter elements according to an embodiment of the present disclosure; FIG. 2 shows a particle separator tube suitable for use with the system shown in FIG. 1, the tube including two filter patches;

FIG. 3 shows a particle separator tube according to an embodiment of the present disclosure, the tube including three filter patches;

FIG. 4 shows an ultrasonic washer according to an embodiment of the present disclosure;

FIG. 5 is a flow chart of steps of a debris analysis process according to an embodiment of the present disclosure; and

FIG. 6 shows the particle separator tube of FIG. 3, with debris particles collected on the filter patches within the tube, according to various embodiments of the present disclosure.

Detailed Description

Various embodiments of the present disclosure are directed to systems, apparatuses, devices, methods, processes, procedures, and/or techniques for separating, extracting and preparing wear or debris particles from a filter element of a filtration device, machine system or machine component to facilitate the analysis, evaluation, characterization, categorization, or classification of the wear condition of the filtration device, machine system or machine component. More specifically, embodiments of the present disclosure are directed to systems, apparatuses, devices, methods, processes, procedures, and/or techniques for debris, wear, or other particle analysis. For simplicity and clarity of description, particulate matter may be generally referred to herein as debris particles. Various embodiments of the present disclosure are described hereinafter with reference to FIG. 1 to FIG. 6, in which like elements are numbered with like reference numerals. Specific details of the described embodiments may be set forth to provide a thorough understanding of the described embodiments. However, it will be understood by a person skilled in the art that the embodiments of the present disclosure as described herein are not precluded from other applications where fundamental principles prevalent among the various embodiments of the present disclosure such as operational, functional or performance characteristics are desired. Fig. 1 is a schematic illustration of a representative system 100 for collecting and analyzing debris particles from a filter element 110 according to an embodiment of the disclosure. In an embodiment, the system 100 includes at least one particle separator tube 200a, 200b, 200c (hereinafter referred to as 200) and a mechanical, vibrational, or sonic energy source, such as an ultrasonic energy source 400, that is configured to agitate or impart, provide, or apply vibrational or sonic energy to the particle separator tube(s) 200. In various embodiments, the particle separator tube(s) 200 can be coupled to, connected to, or carried by the ultrasonic energy source 400. The particle separator tube(s) 200 further includes a set of filtration elements, filters, or filters patches having at least one filter patch 250i, 250ii. Each of the filter patches 250i, 250ii has a predetermined pore size. In some embodiments, the system further includes an optical apparatus (not shown) for examining the debris particles collected on the filter patches 250i, 250ii.

Particular elements of the filter element analysis system 100 are structured in a manner that enables or facilitates (1) dislodgment of debris particles from a filter element 110 and (2) separation of the debris particles into portions according to the size of the debris particles using ultrasonic energy. For instance, a particle separator tube 200 can be structured, shaped, configured and/or machined for carrying, holding, or receiving a filter element 110 in particular location, position and/or orientation so as to subject the filter element 1 10 and the debris particles carried by the filter element 110 to ultrasonic energy. The ultrasonic energy source 400 can be -structured or configured to provide ultrasonic energy for dislodging the debris particles carried on the filter element 110. The set of filter patches 250i, 250ii can be structured and configured for selectively inhibiting the displacement of dislodged debris particles which have a size larger than the pore size of the filter patches 250i, 250ii. The filter patches 250i, 250ii can be arranged in particular orientations or positions relative to each other within the particle separator tube 200 for separating the multi-sized debris particles and collecting the debris particles based on the size of the debris particles.

FIG. 2 shows a particle separator tube 200 according to an embodiment of the present disclosure. In general, the particle separator tube 200 is an elongated or cylindrical receptacle having at least one fluid carrying channel. In multiple embodiments of the present disclosure, the particle separator tube 200 is used for receiving, carrying, or containing a fluid or solvent 205 therewithin. The solvent primarily acts as a cleaning medium for enhancing the removal of debris particles from a filter element 110 using ultrasonic washing. The solvent can be, for example, any of a hydrocarbon based cleaning solution such as petroleum spirit, heptane, acetone, pentane, toluene, petroleum ether and the like. Depending upon embodiment details, the type of solvent used can be selected based on the nature and quantity of debris particles present on a filter element. For instance, if a large quantity of resilient debris particle is present on the filter element, a more suitable solvent should be used to free the debris particles from the filter element.

In various embodiments, the particle separator tube 200 includes a plurality of separable portions, segments, or parts, each of which has an opening and a fluid carrying channel. Referring to FIG. 2, in an embodiment the particle separator tube 200 can include a lid 210, a top part 220, a middle or body part 230, a bottom part 240, a drain plug 260, and a number of filtration elements, filters, or filters patches 250i, 250ii. The lid 210, the top part 220, the body part 230, the bottom part 240, the drain plug 260, and the number of the filter patches 250i, 250ii can be coupled or assembled together to form the particle separator tube 200. In a particular embodiment, the lid 210, the top part 220, the body part 230, the bottom part 240, the drain plug 260, and the number of the filter patches 250i, 250ii can be assembled or stacked in a serial manner with the filter patches 250i, 250ii being carried or positioned transverse to the fluid carrying channel of the particle separator tube 200.

As described above, the particle separator tube 200 according to an embodiment of the present disclosure includes the lid 210. In multiple embodiments of the present disclosure, the lid 210 is shaped and dimensioned to matingly couple with the top part 220. More specifically, the lid 210 can be shaped and dimensioned for fit coupling to a receiving surface 222 of the top part 220. In several embodiments, the top part 220 is a hollow cylindrical structure that is shaped and dimensioned for coupling to each of the lid 210 and the body part 230 of the particle separator tube 200. The top part 220 of the particle separator tube 200 includes screw threads 224. In a number of embodiments, the screw threads 224 of the top part 220 of the particle separator tube 200 are located distal to the receiving surface 222. The top part 220 of the particle separator tube 200 is configured to receive, carry, or contain a filter element sample 110. The filter element 110 can be a portion of a used filtration device, material, or element extracted or taken from a filtering device, machine system or machine component. The used filtration element can be, for example, part of a used hydraulic oil filter or turbine oil filter, or part of a used engine, or a gear oil filter. The filter element 1 10 includes debris particles of different sizes that have been accumulated onto the filter element 110 throughout the operation of the filtration device, machine system or machine component from which the filter element 110 originates. Determination or estimation of the nature, classification(s), characteristics and/or a quantity or density of debris particles, and more specifically in certain embodiments a relative quantity of debris particles of known size(s), facilitates the measurement or evaluation of the extent of wear of the filtration device, machine system and/or machine component.

In multiple embodiments, the body part 230 is a hollow tubular or cylindrical structure that is shaped and dimensioned for coupling to each of the top part 220 and the bottom part 240 of the particle separator tube 200. The body part 230 includes a first end 232 and a second end 234, which are located on opposite ends of the body part 230. The body part's first end 232 includes a first set of screw threads 236 that are shaped and dimensioned for receiving or coupling to the screw threads 224 of the top part 220. The second end 234 of the body part 230 includes a second set of screw threads 238.

The particle separator tube 200 further includes the bottom part 240. The bottom part 240 is a hollow cylindrical structure that is shaped and dimensioned for coupling to each of the body part 230 and the drain plug 260. The bottom part 240 includes a first end 242 and a second end 244, which are located on opposite ends of the bottom part 240. The bottom part's first end 242 includes a first set of screw threads 246 that are shaped and dimensioned for receiving or coupling to the second set of screw threads 238 of the body part 230. The second end 244 of the bottom part 240 can include a second set of screw threads (not shown) that are shaped and dimensioned for receiving or coupling to the drain plug 260. The drain plug 260 can thus include screw threads 262, which are shaped and dimensioned for coupling to the second set of screw threads of the bottom part 240. The particle separator tube 200 in accordance with an embodiment of the present disclosure includes a set of filter patches 250i, 250ii. The filter patches 250i, 250ii are assembled or secured within the particle separator tube 200 via mechanical means. In the embodiment shown in FIG. 2, a first filter patch 250i is assembled between the top part 220 and the body part 230 of the particle separator tube 200, and a second filter patch 250ii is assembled between the body part 230 and the bottom part 240 of the particle separator tube 200. In several embodiments of the present disclosure, the filter patches 250i, 250ii include screw threads (not shown) formed on the periphery thereof, which facilitates mechanical coupling or assembly of the filter patches 250i,-250ii to either of the top part 220, the body part 230, and the bottom part 240 of the particle separator tube 200. In other embodiments, the filter patches 250i, 250ii do not include screw threads, and may be carried by or positioned upon a seating or support portion of a particle separator tube part 220, 230, 240. Mechanical structures, gaskets, o-rings, or other types of sealing elements can be employed (e.g., as separate elements or as a portion of the filter patches 250i, 250ii or a filter patch assembly) to facilitate fluid sealing within the particle separator tube 200.

Each filter patch 250i, 250ii of the particle separator tube 200 has a predetermined pore size. In various embodiments of the present disclosure, the pore sizes of the filter patches 250i, 250ii are selected in relation to the type of filter element to be analysed. This is because different types of filter elements, more specifically filter elements obtained from different types of used filtration devices (i.e., used hydraulic oil filters, used engine oil filters, or used turbine oil filters), can each contain debris particles of varying or different sizes. In several embodiments, the pore sizes of individual filter patches 250i, 250ii can be selected or determined in accordance with a) an expected range of debris particle sizes corresponding to a given type of filtration device or filter element 110 under consideration; and/or b) a number of particle size gradations or particle size granularity levels of interest.

To inhibit displacement or passage of a debris particle of a particular size through a given filter patch 250i, 250ii, the pore size of that filter patch 250i, 250ii should be smaller than the size of the particular debris particle. Thus, any given filter patch 250i, 250ii can have a predetermined pore size that is approximately equal to a minimum debris particle size that the filter patch 250i, 250ii is configured to retain or capture. For instance, used gear oil filters and used engine oil filters typically contain debris particles that are approximately 1000 micrometers in span, diameter, or width. In order to trap debris particles of approximately 1000 micrometers, the pore size of a filter patch 250i, 250ii should be smaller than approximately 1000 micrometers. In addition, used hydraulic oil filters typically contain debris particles of approximately 5 to 25 micrometers in size. Accordingly, to trap debris particles of approximately 5 to 25 micrometers, the pore size of a filter patch 250i, 250Π should correspondingly be smaller than approximately 5 to 25 micrometers. For example, in some embodiments of the present disclosure, the pore sizes of the filter patches 250i, 250ii are between approximately 800 and 1000 micrometers. Additionally or alternatively, in some embodiments the pore sizes of the filter patches 250i, 250ii are smaller than 800 micrometers, for example, between approximately 5 to 25 micrometers.

In most embodiments of the present disclosure, the first filter patch 250i and the second filter patch 250ii can have a different predetermined pore size relative to each other. For instance, the first filter patch 250i of the particle separator tube 200 can have a coarse pore size, and the second filter patch 250ii of the particle separator tube 200 can have a fine pore size. In a representative implementation, the first filter patch 250i can have a pore size of approximately 1000 micrometers, and the second filter patch 250ii can have a pore size of approximately 800 micrometers. In another representative implementation, the first filter patch 250i can have a pore size of approximately 25 micrometers, and the second filter patch 250ii can have a pore size of approximately 20, 15, 10, or 5 micrometers depending upon embodiment details and/or a debris analysis situation under consideration. Typically, the filter patches 250i, 250ii are positioned or ordered sequentially in the particle separator tube 200 in accordance with their pore sizes, such that a filter patch 250i, 250ii with the coarsest pore size resides closest to the top part 220 where the filter element 110 is carried. Filter patches 250ii having progressively finer pore sizes reside successively further from the top part 220 of the particle separator tube 200. In the particular embodiment shown in FIG. 2, the first filter patch 250i, having the coarsest pore size, can be positioned between the top part 220 and the body part 230, while the second filter patch 250ii, having a finer pore size relative to the first filter patch 250i, can be positioned between the body part 230 and the bottom part 240 of the particle separator tube 200. In several embodiments of the present disclosure, the filter patches 250i, 250ii are made substantially from plastic, or a plastic polymer. In other embodiments, one or more filter patches 250i, 250ii can include a fine wire mesh configured for producing a predetermined pore size (also known as mesh size). The use of the fine wire mesh allows a user to heat the fine wire mesh of the filter patches 250i, 250ii following a washing and separation process such as that described below to observe a response of debris particles trapped thereon to an applied signal, substance, or stimulus, which can involve one or more of an optical, electrical, magnetic, thermal, or chemical stimulus. For example, a thermal response of debris particles trapped on a filter patch 250i, 250ii can be observed for heat applied at a temperature in a range between approximately 150°C and 350°C, and more specifically between about 200°C and 300°C. In general, following a washing and separation process, one or more filter patches 250i, 250ii can be subjected to a set of tests (e.g., thermal, chemical, optical, or electromagnetic tests) to facilitate characterization of debris particles carried thereby. In various embodiments, the filter patches 250i, 250ii can be disposed of after examination. In other embodiments, the filter patches 250i, 250ii can be cleaned and reused in subsequent procedures.

In the embodiment shown in FIG. 2, the particle separator tube 200 includes a set of two filter patches 250i, 250ii. It will be understood by a person skilled in the art that particle separator tubes 200 with different numbers of filter patches 250i, 250ii can be provided by other embodiments of the present disclosure. For example, particle separator tubes 200 according to other embodiments may include a filter patch set having one, three, four, five, or more filter patches. FIG. 3 shows a particle separator tube 300 that includes a set of three filter patches 250i, 250ii, 250iii. The particle separator tube 300 also includes a lid 210, a top part 220, two body parts 230i, 230ii, a bottom part 240, and a drain plug 260. In most embodiments of the present disclosure, each of the lid 210, a top part 220, two body parts 230i, 230ii, a bottom part 240, and a drain plug 260 of the particle separator tube 300 has a similar or analogous type of construction, and function, to the lid 210, the top part 220, the body part 230, the bottom part 240, and the drain plug 260 of the particle separator tube 200 of FIG. 2, correspondingly. With an increase in the number of filter patches, a more detailed, thorough, stringent or extensive separation and/or analysis of debris particles can be carried out. Specifically, debris particles can be divided into more parts or portions based upon debris particle sizes, and/or characterized in greater detail in accordance with a debris particle size distribution.

The size, dimensions, shape, lengths, diameters, and material of the particle separator tube 200 can be varied as required in accordance with embodiment details. The volume of the particle separator tube 200 can be varied depending on any one or more of size or type of the filter element 110 to be analysed and the volume, type or viscosity of solvent used for dislodging the debris particles from the filter element 110.

In several embodiments of the present disclosure, the particle separator tube 200 is made at least partially of a plastic polymer, and is between approximately twenty and thirty millimeters in external diameter and between approximately ten and fifteen millimeters in internal diameter. In various embodiments, the particle separator tube 200 has an external diameter of approximately twenty-three millimeters and an internal diameter of approximately thirteen millimeters. In some embodiments, the length of the particle separator tube 200 can be between approximately five and fifteen centimeters, the length of the top part 220 can be between approximately thirty and thirty-five millimeters, the length of the body part 230 can be between approximately thirty and thirty- five millimeters, and the length of the bottom part 240 can between approximately fifty-five and sixty millimeters.

Referring again to FIG. 1, the particle separator tube 200, 300 can be coupled to an ultrasonic energy source 400 in accordance with an embodiment of the disclosure to facilitate the removal, dislodgment, or displacement of particulate matter from a filter element 110 carried within the particle separator tube 200, 300. In several embodiments, the ultrasonic energy source 400 can be an ultrasonic washer or washing device. In various embodiments, an ultrasonic washer 400 includes a housing 402; a reservoir or chamber 404 carried by the housing 402; at least one set of ultrasound transducers 406; and a liquid medium 410 disposed within the chamber 404. The set of ultrasound transducers 406 is configured to convey or transfer ultrasonic energy to the liquid medium 410. In some embodiments, a set of ultrasound transducers 406 can be mechanically coupled to or built-in (e.g., by way of a diaphragm) to a portion of the washer 400, for instance a bottom portion of the chamber 404. Additionally or alternatively, a set of ultrasound transducers 406 can be disposable within or insertable into the chamber 404 (e.g., lowered into the chamber 404 prior to the onset of a filter element washing process). In a representative implementation, the ultrasonic washer 400 includes a chamber having a length between approximately 15 and 45 centimeters, a breadth between approximately 15 and 45 centimeters and a height between approximately 15 and 45 centimeters. The ultrasonic washer 400 can include one or more set(s) of ultrasound transducers 406 that can generate ultrasonic waves having a frequency or frequency sweep function between frequency limits of approximately 20 and 50 KHz. In some embodiments, the set(s) of transducers 406 can have a predetermined maximum ultrasonic power output, for instance, up to approximately 1000W.

As shown in the embodiment of FIG. 1, the ultrasonic washer 400 can handle a set of particle separator tubes 200, 300. It will be understood by a person skilled in the art that an ultrasonic washer 400 that can handle different numbers of particle separator tubes depending upon embodiment details. For example, an ultrasonic washer according to the embodiment as shown in FIG. 1 can be configured to handle one or more (for example, two, four, five, or more) particle separator tubes 200, 300 simultaneously. The ability to handle multiple particle separator tubes 200, 300 enables the simultaneous (1) washing and removal of multiple filter elements 110, and therefore (2) a simultaneous separation of the debris particles within multiple separator tubes 200, 300 based on debris particle size(s). In addition, as the system 100 can handle multiple particle separator tubes 200 simultaneously, a plurality filter elements 110 can be handled concurrently. In some embodiments, filter elements 110 from different filtration devices, machine systems or machine components can be processed at the same time. This increases the throughput and efficiency of debris particle analysis.

In various embodiments, the ultrasonic washer 400 can include at least one apparatus, means, mechanism, device, or structure for carrying, receiving, or retaining a portion of a particle separator tube 200, 300. A retaining apparatus or particle separator tube handler can maintain the particle separator tube(s) 200, 300 in a fixed position and orientation such that the particle separator tube(s) 200, 300 can be subjected to maximal ultrasonic activity for inducing the separation and dislodgment of debris particles from the filter element 110. In an embodiment as shown in FIG. 4, the apparatus for carrying, retaining, and/or maintaining the particle separator tube can include a tray or a cover 420. The cover 420 can include one or more holes, openings or apertures 422a-f. A given aperture 422a-f can be structured, configured, shaped and dimensioned to provide a coupling fit with a particle separator tube 200, 300. For instance, in some embodiments, an aperture 422a-f can be circular in shape for receiving a cylindrical particle separator tube 200, 300. In a particular embodiment, the cover 420 can carry the particle separator tube 200, 300 in an upright position. In order to maintain the particle separator tube in the upright position, an aperture 422a-f on the cover 420 can be dimensioned to match or at least slightly exceed the cross sectional area or diameter of the particle separator tube 200, 300, such that the aperture can receive and maintain the particle separator tube 200, 300 in a fixed position and orientation. In other embodiments, the lid 210 of the particle separator tube 200, 300 can be dimensioned to be slightly larger than the area or diameter of the aperture so that the lid 210 can act as a stopper to prevent the particle separator tube 200, 300 from shifting or falling into the chamber 404 of the ultrasonic washer 400.

In various embodiments of the present disclosure, the retaining apparatus can be structured, configured and dimensioned to hold multiple particle separator tubes 200, 300, which are separated from each other in accordance with a predetermined distance. In particular embodiments, the retaining apparatus can carry multiple particle separator tubes 200, 300 that are spaced apart (e.g., approximately equally). Additionally, the distance between two particle separator tubes can be at least equivalent to the external diameter of a particle separator tube (e.g. approximately 20 to 30 millimeters) for obtaining reasonable washing and separation results.

In several embodiments, multiple particle separator tubes 200, 300 can be arranged in parallel (vertically), and can be spaced out approximately equally with a gap between the tubes at least approximately equal to a tube size or diameter. An ultrasonic washer 400 can be configured to carry an even or an odd number of particle separator tubes 200, 300, for instance, spatially arranged or organized in a particle separator tube array.

In various embodiments of the present disclosure, the ultrasonic energy source 400 is operable for creating ultrasonic waves in the liquid media 410 surrounding the particle separator tube 200, 300 and correspondingly in the fluid or solvent 205 carried by the particle separator tube 200, 300 for separating debris particles from the filter element 110. The liquid medium 410 can be essentially any fluid, for example, water; and the solvent 205 can be a hydrocarbon based cleaning solution such as petroleum spirit, heptane, acetone, pentane, toluene, petroleum ether and the like.

The ultrasonic energy source 400 acts to produce, create or generate ultrasonic energy waves within the liquid medium 410. The energy imparted to the liquid medium 410 by the ultrasound^' energy source 400 is correspondingly imparted or transferred to the fluid or solvent 205 carried within a particle separator tube 200, which can forcibly separate or dislodge particulate matter or debris particles from the filter element 110, thereby effectively washing the filter element 1 10. The degree of separation of debris particles from the surface of the filter element 110 can be dependent on the duration of ultrasonic activity and the intensity of cavitation provided by the ultrasonic energy source 400. In several embodiments of the present disclosure, the duration of ultrasonic activity and/or the cavitation intensity of the ultrasonic energy source 400 can be varied in order to attain an expected or target level of filter element debris particle removal or washing efficacy. For instance, the cavitation intensity can be varied by adjusting the amplitude and/or frequency of the ultrasonic waves generated by the ultrasonic energy source 400. In some embodiments, the ultrasonic energy source 400 can be programmed or programmable for generating ultrasonic waves having a predetermined amplitude and/or frequency profile for a predetermined duration.

In certain embodiments of the present disclosure, the ultrasonic energy source 400 is operated for creating ultrasound waves having a frequency of at least approximately 20 kHz for about 5 to 30 minutes. In some embodiments, the ultrasonic energy source 400 provides ultrasound waves having a frequency range of between approximately 30kHz to 50kHz for about 5 to 10 minutes. In a particular embodiment, the frequency of the ultrasonic waves can be adjusted to at least approximately 40 kHz and the duration of ultrasonic activity can be adjusted to approximately 5 to 10 minutes. In some embodiments, power applied to the ultrasonic energy source 400 can be adjusted or varied for controlling the amplitude of the generated ultrasound waves. For instance, the power applied to an ultrasonic washer 400 having a predetermined maximum ultrasonic power output of 1000W can be adjusted between a minimum power of approximately 100 W and a maximum power of approximately 1000 W. Additionally, the ultrasonic washer 400 can be programmed for generating ultrasonic waves having various frequency operations. In a particular embodiment, the ultrasonic washer 400 can be programmed to generate ultrasonic waves of a frequency sweep function.

The amplitude, frequency, and/or duration of ultrasonic activity can be varied according to a type of filter element 110 (i.e., filter elements obtained from a type of oil filter) under consideration and/or a type or strength of solvent 205 introduced into the particle separator tube 200, 300. In addition, the amplitude, frequency, and/or duration of ultrasonic activity can be varied according to the viscosity of the solvent introduced into the particle separator tube 200, 300.

As previously indicated, the ultrasonic energy source 400 produces an ultrasonic wave that is transferred or transmitted to the solvent 205 contained within the particle separator tube 200, 300. This results in the formation of compression waves in the solvent 205, whereby the solvent 205 is subjected to an alternating series of compression and rarefaction forces. When a portion of the solvent is subjected to compression, the pressure upon that portion of the solvent is positive. On the other hand, when a portion of the solvent is subjected to rarefaction, the pressure upon that portion of the solvent is negative. When the magnitude of negative pressure exceeds a threshold level, the portion of solvent will fracture under the intense negative pressure. This leads to the creation of cavitation bubbles in that portion of the solvent. The cavitation bubbles continue to grow in size if they are subjected to further negative pressure. However, due to the propagation of ultrasonic waves, the cavitation bubbles will be subsequently subjected to a positive pressure. The positive pressure shrinks the cavitation bubbles to an unstable size, finally resulting in a violent collapse of the cavitation bubbles known as implosion. Implosions result in a radial propagation of shock waves from the site of collapse of the cavitation bubble. Multiple embodiments of the present disclosure utilize cavitations and implosions, which occur due to the ultrasonic waves, to dislodge, displace, separate and remove debris particles from one or more filter elements 110. Specifically, in various embodiments, the debris particles on a filter element 110 may be loosely or somewhat loosely attached to the filter element 110 by weak cohesive forces or ionic forces. With cavitations and implosions occurring between the debris particle and filter element interfaces, coupled with the propagation of shock waves due to the occurrence of implosions, the attractive forces between the debris particles and filter element 110 can be effectively overcome, thereby freeing the debris particles from the surface of the filter element 110.

Debris particles can correspondingly dislodge from the filter element 110, and be displaced a distance along the length of the particle separator tube 200, 300, for instance, as a result of gravitational forces that act upon the dislodged debris particles carried by the solvent 205. In various embodiments, ultrasonic waves and/or gravitational force can act to pull or displace at least a portion of the debris particles through one or more of the filter patches 250i, 250ii, 250iii. It is understood that a filter patch having a pore size smaller than the size of a particular debris particle will impede passage of that particular debris particle through or across that filter patch 250i, 250ii, 250iii. Accordingly, debris particles of a size larger than the pore size of a particular filter patch 250i, 250ii, 250iii are trapped by that filter patch 250i, 250ii, 250iii. In many embodiments, after removal of the coupling between the ultrasonic energy source 400 and the particle separator tube 200, 300, debris particles dislodged from the filter element 110 eventually settle on a filter patch 250i, 250ii, 250iii or the bottom part 240 of the particle separator tube 200, 300. This results in the separation of debris particles from each other, based on the sizes of the debris particles.

In multiple embodiments of the present disclosure, the system 100 can additionally include an optical apparatus for examining the filter patches 250i, 250ii, 250iii, more specifically the debris particles carried or trapped by or on the filter patches 250i, 250ii, 250iii. In various embodiments, the optical apparatus for performing examination of the debris particles on the filter patches 250i, 250ii, 250iii, can be an optical lens, a microscope, or a scanning electron microscope. FIG. 5 is a flow chart of a debris analysis process 500 according to an embodiment of the present disclosure. In a first process portion 502 of the process 500, at least one filter element 110 is taken, removed, or extracted from a corresponding filtration device, machine system or machine component. Conventional extraction or sampling techniques, other than techniques that involves sawing, can be employed for extracting the filter element 110 from the machine system. Techniques that involve sawing are generally avoided as sawing introduces saw-dust contaminants onto the filter element 110 during the extraction phase, which will result in erroneous and inaccurate debris particle analysis results. The size of filter element 110 extracted from the machine system can be variable, and can be varied depending on a number of factors including, but not limited to, the type of oil filter and/or a partial tube volume corresponding to a cross sectional area or diameter of a particle separator tube 200, 300, and/or a distance between the lid 210 and a filter patch 250i that resides closest to the lid 210 of the particle separator tube 200, 300. In several embodiments, the size of the filter element 110 extracted from the machine system is approximately 20 to 30 millimeters in length, approximately 5 to 15 millimeters in width and approximately 2 to 6 millimeters in thickness. In some embodiments, the size of the filter element extracted from the machine system can be approximately 25 millimeters in length, approximately 10 millimeters in width and approximately 4 millimeters in thickness.

In a second process portion 504, at least one filter element 1 10 is introduced into a corresponding particle separator tube 200, 300. In several embodiments, the second process portion 504 can include assembling one or more particle separator tubes 200, 300, e.g., depending upon a number of filter elements 110 under consideration. In such embodiments, this process portion 504 includes assembling and coupling the parts of the particle separator tube 200, 300 based upon embodiment details. In various embodiments, an assembled particle separator tube 200, 300 includes at least two parts (e.g., an upper part and a lower part) between which at least one filter patch 250i resides, such that a filter element 110 can be introduced into one of the at least two parts. In multiple embodiments, an assembled particle separator tube 200, 300 includes a lid 210, a top part 220, a body part 230, a bottom part 240 and a drain plug 260. Depending upon the extent of size separation of the debris particles required, a number of filter patches 250i, 250ii, 250iii (for example, one, two, three or more filter patches), each having a different pore size, can be selected and assembled into the particle separator tube 200, 300. Each of the filter patches 250i, 250ii, 250iii is positioned at a predetermined position relative to another filter patch 250i, 250ii, 250iii within the particle separator tube 200, 300. As described above, the filter patches 250i, 250ii, 250iii are sequentially ordered in the particle separator tube 200, 300 in accordance with their pore sizes, such that a filter patch with the coarsest or largest pore size resides closest to the top part 220 where the filter element 110 is being carried. As described above, the filter patches 250i, 250ii, 250iii can be inserted into the particle separator tube 200, 300 (i.e., coupled to the top part 220, the body part 230, 230i, 230ii, or the bottom part 240) via mechanical means or methods, e.g., by means of screw threads.

In multiple embodiments involving the second process portion 504, the filter element 110 can be introduced into the chamber of the top part 220 of the particle separator tube 200, 300. The second process portion 504 can additionally include the addition of a solvent 205 into the particle separator tube 200, 300. In order to achieve maximal displacement and dislodgment of debris particles from the filter element 110, the volume of solvent 205 added should be sufficient to fill up the chambers of the bottom part 240, the body part 230 and the top part 220 such that the filter element 110 within the top part 220 is substantially covered or entirely submerged by the solvent 205.

In a third process portion 506, the particle separator tube 200, 300 is attached to, coupled to, placed into, or fitted with an ultrasonic energy source 400. As described above, in multiple embodiments of the present disclosure, the ultrasonic energy source 400 is capable of handling, carrying, or coupling to more than one particle separator tube 200, 300. Accordingly, in many embodiments of the present disclosure, multiple particle separator tubes 200, 300, each carrying a filter element 110, can be attached to, coupled to, placed into, or fitted with the ultrasonic energy source 400 for the processing of multiple filter elements 110 in a sequential, simultaneous or generally simultaneous manner.

In a fourth process portion 508, the ultrasonic energy source 400 is activated and each of the particle separator tubes 200, 300 is ultrasonically agitated in response to the ultrasonic waves generated by the ultrasonic energy source 400. In some embodiments where the particle separator tube 200, 300 is immersed in or surrounded by a liquid medium 410, the ultrasonic waves present in the liquid medium 410 can be transmitted to the solvent 205 within the particle separator tube 200, 300. Depending on the nature and quantity of debris particles carried by the filter element 110, the duration of ultrasonic activity and the intensity of cavitation provided by the ultrasonic energy source 400 can be varied to obtain an optimal amount of separation of debris particles from the filter element 110. For instance, if a large amount of debris particles are resiliently bound to the surface of a filter element 110, higher cavitation intensity and/or longer duration of ultrasonic activity can be applied.

A fifth process portion 510 involves dislodging of the debris particles from the filter element(s). As described above, due to the propagation of ultrasonic waves in the solvent 205 within the particle separator tube 200, 300, at least a portion of the solvent 205 undergoes a series of cavitations and implosions. Occurrence of cavitations and implosions breaks the attractive forces that bind the debris particles to the surface(s) of the filter element 1 10, thereby releasing the debris particles from the surface(s) of the filter element 110.

Generally, after the debris particles are freed from the filter element(s) 110, the debris particles can float within the solvent medium in the particle separator tube(s) 200, 300. At least a portion of the debris particles can be displaced along the length of the particle separator tube 200, 300. Specifically, the debris particles can be displaced by ultrasonic waves or drawn by gravitational force along the length of the particle separator tube 200, 300, away from the lid 210 of the particle separator tube 200, 300 and toward one or more filter patches 250i, 250ii, 250iii. Additionally, displacement of the free debris particles along the length of the particle separator tube 200, 300 draws at least a portion of the debris particles to, across, or through at least one filter patch 250i, 250ii, 250iii within the particle separator tube 200, 300, which causes at least a portion of the debris particles to be inhibited from passing through one or more filter patches 250i, 250ii, 250iii based upon debris particle size relative to filter patch pore size.

In many embodiments, the debris particles are separated according to their sizes in a sixth process portion 512 as they are displaced along the length of the particle separator tube 200, 300. In most embodiments of the present disclosure, the filter patches 250i, 250ii, 250iii are each positioned at fixed positions in sequential order based on the pore size of the filter patches, with the filter patch having the coarsest or largest pore size positioned closest to the filter element 110 within the particle separator tube 200, 300. Accordingly, the debris particles can be separated based on their sizes as they are drawn across the filter patches 250i, 250ii, 250iii along the length of the particle separator tube 200, 300. Debris particles of a size at least slightly larger than the pore size of a particular filter patch 250i, 250ii, 250iii will be trapped thereby, and debris particles of a size smaller than the pore size of a particular filter patch 250i, 250ii, 250iii will be able to pass therethrough.

FIG. 6 shows a particle separator tube 300 containing debris particles that have been separated and collected on filter patches 250i, 250ii, 250iii according to an embodiment of the present disclosure. In the embodiment shown, the debris particles collected on the filter patches 250i, 250ii, 250iii can be divided into three size or average size categories, namely large debris particles 310, medium debris particles 320 and small debris particles 330. The large debris particles 310, having a size greater than the pore size of the first filter patch 250i, are inhibited by the first filter patch 250L The medium debris particles 320 and the small debris particles 330, being smaller than the pore size of the first filter patch 250i, are able to pass through the first filter patch 250L However, as the size of the medium debris particles 320 is larger than the pore size of the second filter patch 250ii, they are trapped on the second filter patch 250ii. Similarly, the small particles 330 are able to pass through the pores of the first and second filter patch 250i, 250ii without being entrapped. However, as the third filter patch 250iii has a pore size smaller than the size of the small debris particles 330, the small debris particles 330 are trapped by the third filter patch 250iii.

In a seventh process portion 514, one or more particle separator tube 200, 300 are removed from the ultrasonic energy source 400 and the corresponding filter patches 250i, 250ii, 250iii are removed from the particle separator tube 200, 300. The filter patches 250i, 250ii, 250iii can be removed or extracted from the particle separator tube 200, 300 by mechanical means, tools, devices, or methods. In association with the seventh process portion 514, the drain plug 260 can be removed from the particle separator tube 200, 300 to facilitate drainage of the solvent 205 from the particle separator tube 200, 300. In several embodiments, removal of the filter patches 250i, 250ii, 250iii is done via mechanical means, and is fast and cost- effective. In an eighth process portion 516, the filter patches 250i, 250ii, 250iii are examined, inspected, or tested (e.g., on an individual basis) for characterizing and/or determining at least one of a quantity, size, morphology, and type of debris particles trapped thereby. In multiple embodiments, an optical apparatus is used for examining the filter patches 250i, 250ii, 250iii and more specifically the debris particles collected or trapped by or on the filter patches 250i, 250ii, 250iii. In various embodiments, examination of the debris particles on the filter patches 250i, 250ii, 250iii can be performed via microscopy using an optical lens, microscope or scanning electron microscope. Additionally, the filter patches 250i, 250ii, 250iii can be heated to a certain temperature followed by an observation of a heat response of the debris particles collected or trapped by the filter patches 250i, 250ii, 250iii. Based on the heat response of the debris particles, the material that makes up the debris particles can be deduced or identified. For instance, materials that can be identified by a heat response examination include fibers or elastomer or alloy compositions.

In many embodiments of the present disclosure, the ability to determine at least one of a type, size, and quantity, density or nature of debris particles found on a filter element 1 10 enables a user to estimate or obtain data as to wear (i.e., wear status) of a machine system from which the filter element 110 was extracted. It will be understood that in embodiments of the present disclosure involving multiple particle separator tubes 200, 300, coupled to an ultrasonic energy source 400, particular process portions 502 to 516 can be performed simultaneously for multiple filter elements 110, with each filter element 110 being carried by a particle separator tube 200, 300. Accordingly, the process 500 can be faster and more cost-effective than other techniques for filter debris analysis that are capable of processing or analyzing individual filter elements 110 one at a time. In addition, in several embodiments of the present disclosure, the system 100 is portable and easy to use, and therefore is suitable for on-site machine system or component wear measurement or evaluation. Accordingly, the process 500 according to multiple embodiments of the present disclosure can be versatile, convenient, fast, and cost-efficient.

It will be understood that particular embodiments of the present disclosure can be used for evaluating the particulate content for samples other than filter elements. For example, various embodiments of the present disclosure can be used for determining at least one of a size, morphology, and type of particles found on a specific part or component (for example, a gear or housing) of a machine or device.

In the foregoing description, embodiments of the present disclosure are described with reference to the figures. Numerous changes and modifications can be made to the described embodiments of the present disclosure without departing from the scope or spirit of the present disclosure. The scope of the disclosure as well as the scope of the following claims is not limited to embodiments described herein.

Claims

1. A method for analyzing debris particles from a set of filter elements, comprising:

introducing the set of filter elements into a set of particle separator tubes, each particle separator tube within the set of particle separator tubes comprising a set of filter patches having a predetermined pore size;

agitating the set of particle separator tubes using ultrasonic energy for dislodging the debris particles from the set of filter elements; and

collecting a portion of the debris particles on the set of filter patches, wherein each filter patch within the set of filter patches has a predetermined pore size configured to capture debris particles having a size larger than the predetermined pore size.

2. The method of claim 1, wherein the set of particle separator tubes comprises a plurality of particle separator tubes, the plurality of particle separator tubes comprising a first particle separator tube and a second particle separator tube.

3. The method of claim 1, wherein agitating the set of particle separator tubes comprises agitating a plurality of particle separator tubes simultaneously.

4. The method of claim 2, further comprising introducing a first filter element of the set of filter elements into the first particle separator tube and a second filter element of the set of filter elements into the second particle separator tube.

5. The method of claim 4, wherein the first filter element and second filter element are from different sources.

6. The method of claim 1, wherein at least one of the particle separator tubes within the set of particle separator tubes comprises a plurality of filter patches.

7. The method of claim 6, wherein each of the plurality of filter patches has a different predetermined pore size.

8. The method of claim 7, wherein the plurality of filter patches is arranged in a serial manner.

9. The method of claim 8, wherein the plurality of filter patches is arranged according to the predetermined pore size of the filter patch, with a filter patch having the largest predetermined pore size positioned closest to the filter element.

10. The method of claim 1, further comprising introducing a solvent into each of the particle separator tubes within the set of particle separator tubes.

11. The method of claim 1, wherein the ultrasonic energy is provided by an ultrasonic washer.

12. The method of claim 1, wherein the ultrasonic energy is provided by an ultrasonic wave having a frequency of about at least 20,000 Hz.

13. The method of claim 1, wherein the ultrasonic energy is provided by an ultrasonic wave having a frequency of less than about 50,000 Hz.

14. The method of claim 1, further comprising:

extracting the set of filter patches; and

examining the debris particles collected on the set of filter patches.

15. A system for analyzing debris particles from a set of filter elements, comprising:

a set of particle separator tubes, each particle separator tube within the set of particle separator tubes configured to carry a filter element; and

an ultrasonic energy source for agitating the set of particle separator tubes to dislodge the debris particles from the set of filter elements,

wherein each of the particle separator tube within the set of particle separator tubes comprises at least one filter patch having pores of a predetermined pore size for collecting debris particles having a size larger than the predetermined pore size of the at least one filter patch.

16. The system of claim 15, wherein the set of particle separator tubes comprises a plurality of particle separator tubes, the plurality of particle separator tubes comprising a first particle separator tube and a second particle separator tube.

17. The system of claim 16, wherein the first particle separator tube carries a first filter element of the set of filter elements and the second particle separator tube carries a second filter element of the set of filter elements.

18. The system of claim 17, wherein the first filter element and the second filter element are from different sources.

19. The system of claim 15, wherein at least one of the particle separator tubes within the set of particle separator tubes comprises a plurality of filter patches.

20. The system of claim 19, wherein each of the plurality of filter patches has a different predetermined pore size.

21. The system of claim 20, wherein the plurality of filter patches is arranged in a serial manner.

22. The system of claim 21, wherein the plurality of filter patches is arranged according to the predetermined pore size of the filter patch, with a filter patch having the largest predetermined pore size positioned closest to the filter element.

23. The system of claim 15, wherein the ultrasonic energy source is an ultrasonic washer.

24. The system of claim 15, wherein the ultrasonic energy source is configured to carry a plurality of particle separator tubes in an array arrangement.

25. The system of claim 15, wherein the ultrasonic energy source is capable of generating an ultrasonic wave having a frequency of about at least 20,000 Hz.

26. The system of claim 15, wherein the ultrasonic energy source is capable of generating an ultrasonic wave having a frequency of less than about 50,000 Hz.

27. The system of claim 15, wherein the at least one filter patch is separable from the set of particle separator tubes.

28. The system of claim 15, further comprising an optical apparatus for examining the at least one filter patch for determining at least one of quantity, size, and morphology of the portion of debris particles carried thereby.