home Training Machine for the production of air filters. Manufacture of oil filters. Air filters for cars

Machine for the production of air filters. Manufacture of oil filters. Air filters for cars

At least after every 10,000 miles, the driver who cares about his car changes the air filter. Thus, we can conclude that this is a product, the demand for which will always be. The production technology is simple, and the equipment for the production of filters for cars is relatively inexpensive, which attracts entrepreneurs who want to master this line of business.

Air filter functions

The main task of an automobile air filter is to clean the air entering the engine. A good detail, subject to its timely replacement, retains up to 99% of "foreign" particles contained in the air. A quality product does not lose its properties throughout the entire service life. In addition to directly filtering the air, it also dampens noise and regulates the temperature. Thanks to the air filter, the risks of various damage to the car engine are significantly reduced, and wear and tear of parts is also minimized.

Types of air filters for cars

It is possible to manufacture air filters for cars from paper, and they can also be inertial oil or carbon. The shape may also be different. Equipment for the production of filters for cars uses a special raw material - cellulose fiber paper. It is protected by a special impregnation, so that it is not afraid of water, oil or fuel. Paper products do a better job of their direct task, so they are somewhat more expensive than coal products. The filtering ability is further enhanced by the fact that the paper is folded into an accordion.

Various designs of air filters

The following types of paper filters are distinguished by shape:

cylindrical;
panel;
frameless.

Cylindrical air filters are mainly used in cars with carburetor type engines. In modern passenger cars, mainly panel-type products are used. This design is optimal, since with its small volume the filter has a large filtration area.

How to produce car filters

The production technology of air filters is quite simple. It lies in the fact that a special rotating drum feeds the paper between two rotating cylinders, which bend it, making an accordion. The counter counts the same number of folds. After that, the paper is sent along a conveyor belt to a circular saw, which makes a cut at regular intervals.

The upper and lower parts of the filter are made using aluminum molds coated with liquid wax and liquid polyurethane. All operations with molds, namely waxing, filling with polyurethane, subsequent transfer of the finished product to the cooling grid, are carried out by a manipulator.

The equipment for the production of filters for automobiles is an almost completely automated line, which can only be serviced by one worker. Its tasks include laying blanks of corrugated paper on the bottom of the filter, extracting finished products from the chute into which they fall after the manipulator has finished its work. Packing of finished products is also carried out by the line operator. Thus, a complete production cycle takes approximately 20 minutes.

You can assemble a line from its component parts. However, by purchasing ready-made, assembled and configured equipment, you can minimize labor costs, maximize work productivity, and also protect yourself from problems with the maintenance and repair of devices.

The purpose of automotive filters is, by its basic definition, to keep the engine free of contaminants found in air, fuel, and oil. Filters perform inconspicuous, but necessary work, both for engines and units, and for humans.

Equipment for the production of

The production of filters is carried out on equipment of various designs. This may be an automated technique that is needed in order to perform various production operations to form a sealing contour. And also for the manufacture of end sealed elements in filters, both large and panel type. With the use of modern technology for applying non-foamed and foamed polymer, they began to be used for the production of filters of various types. Namely: air, oil, air conditioning, aspiration, fuel and automobile filters.

The advantages of this equipment include the following qualities: dosing systems and precision work coordinates that will provide high-precision application. Quick payback of equipment, low cost of raw materials, ease of implementation at the production stage. As well as a high level of automation, which increases automation, which increases practicality and productivity.

Now let's look at the technology for the production of round-shaped filters, which also do not need to be bypassed. The production of round-shaped filters consists in the phased pouring of the foam system into the mold. At the moment of solidification, an end hermetic element is formed, also of a round shape. Filter production takes place on a dosing machine operated by only one operator. AT manufacturing process use a non-foam system to get extra protection in wet environments.

As for the production of panel-type filters, it is based on the operation of applying a foam system along the sealing line onto a special frame. Such an operation is carried out using a high-precision coordinate manipulator, as well as a precision dosing system, and, of course, a low-performance mixing device. Such work is considered invisible and imperceptible.

Those filters that are used in diesel or gasoline engines are considered complex devices due to their simplicity. If we talk about filters as a separate device, then it will be completely meaningless. Since the filter is considered an integral part of one organism, which is called the engine. These filters are great for one engine, but they don't have to be as they can work on other models as well.

In addition to the filter element, such filters have 3 types of valves, namely: anti-drainage, return and bypass. Each of them is made for a certain pressure and flow rate, which ensures uninterrupted operation of the engine at the time of its start. As for the viscosity of oil, fuel, and air dust content, they will differ significantly under different conditions, and the design of the filter must ensure operation under any conditions. It is also worth considering that the oil in the engine will be intensively contaminated and not only during the break-in period. First of all, the oil undergoes natural aging and oxidation.

Air filter technology

The production of filters begins with a fine fuel filter, and consists of a paper filter element, as well as a polyamide housing. A filter curtain is connected to the end discs, which are made of galvanized steel using a special plastisol method. After that, the filter element is inserted into the polyamide housing, which is welded to the cover by high-frequency welding. As for the tightness of the filter, it is tested under a pressure of 2.5 atm. Then a marking is applied, which should correspond to this type of filter.

The production of filters with oil inserts, and fuel, air filters are similar to the production of filter elements, the only difference is the replacement of the polyamide housing with a metal frame that looks like a grid. The end rings of the air filter are made of PVC-based plastisol, and only after that they are poured into special molds. A paper curtain, which is made in the form of a star, is inserted into the liquid mass. After that, the filter passes through an oven, in which the plastisol is gelled under the influence of high temperature, and the result is an elastic, resistant, compact material. Each filter, before applying marking and labels, pass one hundred percent quality control.

Video how to do it:

Today, many enterprises need to modernize production. Introduction modern technologies in this field of activity provides an opportunity to improve the quality of products and reduce the price, and this is considered the main factor in the conditions high level competition.

The well-known Belarusian company SOAO "DIFA" has been producing air filters for cars for more than five years and occupies a leading position in the market of Russia and the CIS countries. The range includes a wide selection finished products. Also LLC "DIFA-AVK" is engaged in the manufacture of air filters to order.

We offer filters and filter elements highest quality at the best prices. Our products annually successfully pass ISO/TS16949:2009 quality certification. Here you can order reliable air filters for cars and trucks.

What is an air filter for?

The air filter is an integral part of a car engine. It is designed to trap dust, soot and other small particles. A defective or clogged filter can cause engine damage. Therefore, timely replacement is the key to a long service life of your machine.

The air filter can be integral or consist of a detachable housing and a replaceable filter element. The filter material is made from special grades of paper. It is protected from exposure to various types of liquid and condensed air. Air filters from DIFA can eliminate over 98% of contaminants.

Air filters for cars

In passenger cars, two types of filters are used: rounded and panel. The former have a cylindrical or annular filter element. In order to prevent damage to the filtering partition, protective elements that increase its strength are used. Most often, these are metal meshes with a stainless coating.

In a number of rounded filters, pre-cleaners are used: additional filtering partitions. Their task is to provide preliminary air purification, retaining large particles so that they do not clog the main partition. Due to this, the device can last much longer.

The second type of filters - panel. They have a flat design and are used in almost all modern models of passenger cars. More modern, they are gradually replacing outdated round filters. The manufacturing technology of such filters is much more complicated. This is due not only to the shape of the partition, but also to the need to use additional elements that increase the rigidity of the device. These can be glued seams or meshes made of metal or plastic.

Air filters for trucks

Engines trucks, consume more air due to their significant volumes. In addition, such cars, as a rule, cover a much greater distance per year than passenger cars. This means that there will be more demand from air filters for trucks.

Classic design

In the production of air filters, attention is primarily paid to increasing the rigidity and strength of the filter element. This is ensured by external mesh shells and additional reinforcing metal elements. Seals installed on the covers provide maximum tightness of the filter element in the housing.

Modern design

In the design of modern devices, additional safety elements are assumed. These are additional filters with a smaller diameter. They are inserted inside the main filter elements. Their task is to protect the engine of the car if the main filter element was destroyed.

foreign brands

First of all, congratulations to the MANN+Hummel Group, which won a convincing first place. We were also pleased with the good results of the top 5 Russian brands - especially considering the fact that in 4 cases out of 5 they produce products at home. In the overall standings, these five took 5th (BIG Filter), 6th (Livny), 8th (Nevsky Filter), 12th (TSN Citron) and 15th (Goodwill) places, respectively.
Now about other impressions. Summing up, we studied the distribution of points between brands and found that there is a clear leading group: 10 foreign brands and 5–6 Russian ones. All other brands lose sharply to this group.
By and large, the distribution of points shows that there is room in the market for 15-16 trademarks intended for a wide audience. Each of them can occupy its price-quality niche or attract buyers with other advantages that competitors do not have.
The figure can be easily explained by the laws of consumer psychology: even a professional buyer is not able to master more than a dozen brands and maintain close contact with them.
Do other brands have to die? Not necessary. After all, we were talking about a wide audience, but there are still narrow niches that need special products and a different sales system: motorsport, military-industrial complex and others. Enough space for everyone. Provided that manufacturers leave the price war, look for their unique buyer and find a unique way to satisfy him.

Top 10 Foreign Brands

1 place MANN filter Country: Germany Turnover - 3.04 billion euros Number of employees - 16.6 thousand. The MANN + Hummel concern is several times larger in terms of turnover than any of its competitors; alone main plant The company produces 170 million filters per year. He owns a number of important innovations, including the paper filter element in air and oil filters (1951). MANN also has factories in many countries, including Russia, as well as subsidiaries producing filters under other brands.	2nd place Knecht Country: Germany Turnover - 600 million euros (Department of filters Mahle) The number of employees is about 4 thousand (department Mahle filters) Number of employees in Russia - n. d. Knecht has been producing filters since 1899, focusing mainly on European the lineup. A number of his innovations have become industry standard - for example, the first paper filter element in Europe. In 1972, the process of Knecht joining Mahle began, stretching for more than 20 years, but even after that the spirit of leadership and innovation did not disappear. Knecht was one of the first to introduce filters with an accordion element, two-stage diesel filters with water separation and oil filters with a plastic housing.	50 million units market volume automotive RF filters .
3rd place Bosch Country: Germany Turnover in the world in 2015 - 70.6 billion euros Number of employees in the world / in Russia - 375 thousand / 1700 Filters are not the segment and product where Bosch excels innovation. The world's largest auto supplier deals with them, rather, out of business necessity, preferring to create joint enterprises with partners who "ate the dog" on the filters - for example, MANN and Denso. However, the overall high reputation Bosch brand allowed her to take a high 3rd place.	4th place Filtron Country - Poland Turnover - n. d. Number of employees - n. d. Number of employees in Russia - n. d. Combining WIX-Filtron, with 2016 owned by the concern MANN+Hummel is considered the fourth largest filter manufacturer in Europe with a 70 million pieces per year, working not only in the secondary, but also in the OEM / OES market of the European Union. The post-Soviet world is also an important territory for Filtron: 10 years ago, the company opened production in Ukraine, and after 3 years office in Russia.	5th place Fleet Guard Country: USA Turnover - $19.2 billion (Cummins in 2014) Number of employees - 54600 (Cummins in 2014) Number of employees in Russia - n. d. The Fleetguard brand is owned by Cummins Cummins Filtration. Its strong position in Russia reflects, first of all, market the strength of the engine-building concern itself.
$300 million the size of the automotive market RF filters	6th place Hengst Country: Germany Turnover - n. d. Number of employees - n. d. Number of employees in Russia - n. d. Hengst is a family business 3rd generation controlled Jens Röttering, grandson of the founder Walter Hengst's company manager. Hengst is a permanent member nickname of the IAA exhibition since 1962, and tor- brake pads for Porsche supplied has been burning since 1968. Even a strong fire, destroyed the company's plant in eighties, did not break Hengst, the company literally reborn from the ash.	7th place Sakura Country - Indonesia Turnover - n. d. Number of employees - n. d. Number of employees in Russia - n. d. The Sakura brand is not from Japan, and from Southeast Asia. The ADR group that owns it in 1976 acquired a factory specializing in on filters. Aiming to Western markets, ADR wisely started by buying a license from America Riccan rival Donaldson company. Now Sakura annually produces about 100 million films trov and is included in the Top 100 companies, contributed the most to growth well-being of the population of the Asia-Pacific region.
8th place FRAM Country: USA Turnover - n. d. Number of employees - n. d. Number of employees in Russia - n. d. Founders of FRAM Group IP (now part of the Sogefi group) Frederic Franklin and T. Edward Aldam - the same people who invented easily replaceable filter element. The famous Studebaker trucks supplied to the USSR under Lend-Lease had FRAM filters. Currently the company is considered the largest manufacturer of filters for large equipment with its own full production cycle. 40% diesels made in the USA carry FRAM filters.	9th place Champion Country: USA Turnover of Federal-Mogul in 2014 - $7.3 billion Number of Federal-Mogul employees in 2014 - 48600 Number of employees in Russia - n. d. Initially, the Champion company (and it has been over 100 years old) specialized in candles, but in 1998, it came under the control of Federal-Mogul and the cult brand became the umbrella brand for parts and consumables. According to a number of sources, Champion components are in 8 out of 10 new cars.	10th place SCT Germany Country: Germany Turnover - n. d. Number of employees - n. d. Number of employees in Russia - n. d. In our rating Sudheimer Car Technik - Vertriebs GmbH is the only merchant around industrialists. SCT started in 1993 with the sale of a wide range of spare parts. Getting rich, the company began to acquire factories - for example, the production of lubricants in Lithuania. Filters the Germans have been producing since 1998 and they have it works out well, which is confirmed by this rating.

Top 5 Russian brands

1 place BIG Filter Turnover - n. d. Number of employees in Russia - n. d. In the overall standings of our ranking BIG Filter took 5th place. Is not only the most durable Russian brand, it is also the most successful exporter among manufacturers filters - in 2015 the company delivered products abroad 100 million rubles She is also successful in in the secondary market, and in dealer networks automakers. BIG Filter even participated in the development of stuffy system for Bentley.	2nd place Livny (LAAZ) Headquarters - Livny, Oryol region. Turnover - n. d. Number of employees in Russia - n. d. Filters "Livny" (LLC "Avtoagregat ”) for the third year become the best with our domestic filters World Automotive Awards Components". By own estimated that the enterprise holds 80% primary filter market in the Russian Federation. Moreover, this status is “Autounit” has been holding since 1966: LAAZ has become the first in our country to specialize authorized manufacturer of this products, supplier of young factories VAZ and KamAZ.	3rd place Nevsky filter Headquarters - St. Petersburg Turnover - n. d. Number of employees in Russia - n. d. CJSC PKF Nevsky Filter - the main asset of the Rollman group, specializing in ske filters and filter elements. This year, the yatie will celebrate the 20th anniversary of the vaniya and 10th anniversary of accession Engelsky Filter Plant, which became the second production site of the Nevsky Filter.
4th place TSN Citron Headquarters - Moscow Turnover - n. d. Number of employees in Russia - n. d. Another company with a long history industrial roots. Citron started in 1968. as a radio plant in the structure of the military-industrial complex, built in Mikhailovsk, Stavropol Territory. In 1991 he passed into private ownership; then there was a car mobile theme - "Citron" mastered the production of system parts we ignition, and 4 years later and filters. Now the Mikhailovites are working on German technologies, and the products are demand not only in Russia, but also in Eastern Europe.	5th place Fortech Headquarters - Moscow Turnover - n. d. Number of employees in Russia – n. d. Company "Fortek-Auto", owner brand Fortech, specialized in automotive filters, pads, clutches, and in the last 6 years also in automotive optics. She pays special attention consumables for VAZ cars and GAZ. And Fortech components for foreign car brands are sold not only in Russia, but also in Europe, South America and Southeast Asia.

Oil filters - designed to prevent engine wear by cleaning the oil from contaminants in the process of its circulation. The range of oil filters consists of more than a hundred items for most well-known car models. Our company does not stand still, developing and introducing new filter models into production, constantly improving their production technologies, which allows it to satisfy the needs of even the most picky car enthusiast. New technological testing lines introduced by our company into production make it possible to guarantee high reliability in the operation of oil filters that enter the shelves of stores around the world. Oil filters manufactured by GS INDUSTRY LLC are assembled on modern certified South Korean-made equipment using materials and components that meet all the requirements of quality standards.
Schematic diagram of the oil filter. All metal parts of the filter are made of high quality steel leading Russian manufacturers, capable of withstanding all the loads that the filter is subjected to during its service life without changing its properties. Internal pressure, which does not cause destruction of filters, 20kgf/cm2. Assembly of the filter element. The tightness of the filter, like all other technical parameters, is confirmed by regular checks in a special laboratory with unique equipment that simulates the operation of the filter in real conditions. Checking the operating parameters of filters in the laboratory. Summing up, we can safely say that the filter produced by GS INDUSTRY LLC meets all the most stringent production and quality standards, which guarantees safety and extends the life of the engine. Tips for those wishing to purchase an oil filter Experts advise paying attention to the following components of the device: filter housing, filter element, spring, anti-drain valve, cover, o-ring and packaging. According to them appearance and condition, you can objectively judge the quality of the cleaning device and decide directly on the spot whether it is worth buying or not. It is desirable that the name of the manufacturer with its coordinates be written in Russian on the package. The body must be solid, not succumb to deformation from pressing with your fingers. Strength is necessary for him, since he is located on the bottom, respectively, subject to damage by any solid object that accidentally flew out from under the wheel or fell under the bottom of the car. In addition, the housing must be able to withstand the pressure drops that occur in the oil flow, especially in cold weather.