Filter Pleat Crimping System

Project Description:  This system is a custom non-robotic machine designed to crimp the edges of pleated filter packs.   

Operation:  The system starts with a pre-processed pleated filter media “pack”.  This pack is then moved and trapped in a predetermined location on the main crimp deck.  The pack is then compressed laterally to control tension, then crimped in a successive series of steps across both edges simultaneously.  Approximately 8000 psi is generated on the pack during the crimping operation.     

Mechanical Architecture:  The system is on a custom heavy duty 80/20 frame, with control enclosure underneath, and all operational hardware on the top deck for easy maintenance.  

Motion:   

Part Load/Unload:  Fully pneumatic under PLC control.    

Sensors:  Proximity, Inductive, through-beam and magnetic.     

Vision:   N/A 

Safety:  System is fitted with a perimeter safety frame and standard light curtains.       

Primary Challenges and Solutions: 

1. Multiple Pack Widths:  The system needed to accommodate 4 different pack lengths, with changeover requirements of less than 5 minutes.   

Solution:  One side of the crimping ram system was configured to allow lateral movement with hard stops being provided for each of the separate pack lengths.  This had the added benefit of being adjustable in case of dimensional drift in upstream processes.  

2. High Crimping Forces:  The product required a great deal of force to reliability crimp to the size and tolerances needed.   

Solution:  Multi-power pneumatic cylinders were used which allowed sufficient crimp force to be applied without the need for the expense (and potential contamination) of a hydraulic system.  Further, the “stepped” approach of the crimping process further reduced the ram pressures needed to a degree that the process could be comfortably accommodated with purely pneumatic power. 

3. Pack Edge Integrity:  The crimping forces necessary distorted the edges of the pack to such a degree that bond lines could not be successfully established.   

Solution:  A lateral gate was developed and integrated that provided sufficient lateral pressure to restrain the pack edges during crimping.  The result is a clean/straight bond line on every part, regardless of input conditions.