ARGO-HYTOS sets standards in the wind power sector with EXAPOR®MAX 2
Competitive advantages for manufacturers and operators of wind power systems thanks to an innovative development from ARGO-HYTOS
As one of the world's leading manufacturers of innovative solutions for the hydraulics industry, ARGO-HYTOS has opened a new chapter in the history of hydraulic filtration with the introduction of EXAPOR®MAX 2.
The requirements of machine operators in the area of mobile and industrial hydraulics for ever-greater machine availability, longer service intervals, lower-cost spare parts, and lower operating costs were both the motivation and the objective for the development of the EXAPOR®MAX 2 filter element.
Significantly reduced pressure loss, improved clogging capacity
To improve the performance density of the filters, in addition to increasing clogging capacity, it is also necessary to reduce pressure loss.
Using flow simulations ARGO-HYTOS has succeeded in gaining knowledge about the conditions in the fold channel. ARGO-HYTOS has been able to identify the key influence factors responsible for pressure loss in the folded material. The result is a special web technology for production of the new hybrid fabric that ensures that optimal opening of the fold channels is maintained. Thus pressure loss in the fold is reduced by as much as 50%. It was possible to impressively implement the findings obtained in the simulation in practical application, and confirm them in numerous trials.
Reduction of pressure loss in the filter element by as much as 40% at constant flow rate inversely means that at a specified pressure loss, a flow rate that is up to 65% higher can be realized with the EXAPOR®MAX 2 filter elements.
When configuring hydraulic systems, depending on the application, a smaller filter size can be used, and thus weight, resources and costs can be saved.
Due to the reduction of pressure loss in existing systems this means that the bypass valve opens less often and for a shorter period to protect the filter elements. Consequently fewer particles get through the bypass to the pure oil side and the danger of malfunction due to non-filtered oil is significantly reduced.
The performance-optimized structure of the new 3-layer filter material consists of various fine glass and polyester fibers. This new type of material matrix in the pre-filter and ultra-fine filter materials of the EXAPOR®MAX 2 filter elements significantly contributes to improvement of clogging capacity; for example clogging capacity could be increased by as much as 60% in filter fineness 5 µm(c).
The unusually low differential pressure and the high clogging capacity of the EXAPOR®MAX 2 filter elements enable long service intervals and outstanding cold start characteristics.
Filter elements that satisfy the most rigorous requirements at varying flow rates
Depending on the application, filter elements are subject to strong flexural fatigue stress induced by volume flow and pressure fluctuations, for example in hydraulic pitch adjustment systems.
Due to the flow rate fluctuations, differential pressure changes occur on the filter element, which results in the flexural fatigue stresses referred to above. The fabric that has been developed and patented by ARGO-HYTOS consists of a mix of stainless steel and polyester fibers; in this combination all the advantages of metal and plastic fabrics are exploited and the disadvantages of pure metal or plastic fabrics are effectively avoided. The stainless steel threads arranged longitudinally ensure dissipation of electrostatic charges, which effectively prevents damage to the filter material and the associated worsening of oil purity. The polyester fibers arranged transverse to the metal threads ensure optimal flexural fatigue strength and avoidance of fatigue failure.
Improved flow fatigue characteristics, differential pressure stability, as well as safe dissipation of electrostatic charges significantly contribute to the long service life of the filter elements.
Introduction of copy protection
The plastic sheathing shrink-fit onto the filter bellows, not only improves the technical aspects, it also enhances the visual impression that emphasizes the quality of the products. The plastic sheathing is customer-specifically and individually imprinted. All EXAPOR®MAX 2 filter elements are fitted with this feature which clearly increases the recognition value of the filter elements.
In this manner it is easy to externally differentiate originals from copies.
Thus all machine operators who value quality and safety will have the possibility of easily verifying the authenticity of the filter elements.
This measure is just one of the many measures of an extensive copy protection concept to protect the products and offer advantages to the customers.
Summary of a successful leap in innovation
Benefits from the use of Exapor Max 2 filter element technology:
- Increased operational reliability: The risk of sudden machine failure and downtime of windnenergy plants can be significantly reduced. Maintenance intervals can be extended, resulting in significant cost and time savings.
- Because of the significantly higher dirt holding capacity, the filter element changeover period can be extended. For wind power plants with time-based maintenance intervals, the service life reserve and operating reliability is increased.
- Improved oil cleanliness extends the wear service life of components and of the hydraulic and lubricating oils.
- Significant reduction in pressure loss combined with improved dirt holding capacity results in a higher performance density that enables the use of smaller filters, depending on the application.
- In the fight against product pirates the increased copy protection thanks to customized geometries of EXAPOR®MAX 2 filter elements is an important feature for expanding and assuring the strategic spare part business.
Overall, the EXAPOR®MAX 2 filter element technology can be an important factor for an increased productivity and profitability of wind power plants.