A Powerful Ally for Gearbox Protection: Steel Mill Edition - Special Magnetic Filter
Magnet Filter MAGNOM (Magnum)
Originally developed to improve the durability of F1 race engines, the magnetic filter is effective in protecting the lubrication circuit of the cold rolling line in steel mills.
By introducing "Magnum" to the line, we can significantly reduce costs such as repair expenses, parts costs, and downtime. "Magnum" was originally developed to improve the durability of F1 racing transmissions. This is a performance report from a major steel company in Malaysia with a site area of 500 acres. Here, they were troubled by the accumulation of iron contamination in the transmission lubrication circuit of the cold rolling line. Even with two existing filter systems, fine iron contamination remained in the bearing lubrication circuit. With the introduction of Magnum, it was confirmed that a significant amount of visible iron contamination was captured in just 16 days! Following the trial of Magnum, the maintenance manager was convinced of the effectiveness of Magnum technology based on survey results showing improved oil cleanliness. Due to the positive test results, they decided to purchase an additional seven units for other lines. Our maintenance team was relieved to find that by introducing Magnum, they could eliminate the most harmful iron dust in the line, finally putting an end to the cycle of wear.
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basic information
■Removal of fine particles is possible Magnum can capture fine magnetic particles (submicron: 10μm to 0.07μm) that cannot be removed by filters using filter paper or mesh, such as cartridge filters. ■No clogging Due to its special structure, where magnets are sandwiched between special plates, it does not block the flow path in the area where iron powder is captured. Therefore, it does not cause any clogging or pressure loss. Even when the capture capacity limit is reached, it does not hinder the operation of the device. ■Powerful capturing ability The magnets enhance the magnetic flux through a special arrangement, resulting in a significant difference in the capturing ability of iron powder compared to simple magnets. Unlike conventional magnetic filters, which can only capture contaminants from liquids close to the magnets, this structure greatly improves the cleanliness of the fluid. ■No re-release Captured contaminants are stored in a powerful accumulation area separate from the flow path. The dangerous phenomenon that can occur with regular magnetic filters, where the magnetic force weakens as the distance from the magnet increases, allowing once-captured and solidified contaminants to re-release as a lump, does not happen at all.
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Applications/Examples of results
By Industry ■ Hydraulic Systems Hydraulic power units for factories / Hydraulic devices for processing machines, etc. / Hydraulic testing equipment / Construction machinery / Ships Mining machinery / Agricultural machinery / Railways / Large transmissions / Transmissions for wind power generation devices / Transmissions for coal pulverizers in thermal power plants / Transmissions for kilns and coal pulverizers in cement plants / Transmissions for feed roller drives in factories / Transmissions for mixing and calendar machines in factories / Transmissions for crushing, grinding, and refining processes in mines and metal manufacturing plants / ■ Automobiles and Motorcycles Transmission oil / Power steering / Engine oil ■ Water Cooling and Heating Systems Cooling systems for injection molding molds / Industrial and power generation cooling lines Industrial and power generation steam lines (liquid only) / Cooling liquids for steelmaking lines Quenching liquids / Cutting fluids for processing machines and machine tools / Lathes, milling machines, etc. Processing oils for electrical discharge machines / Various cleaning liquids / Quenching cooling liquids
Detailed information
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Challenges of conventional filtration methods Microparticle contaminants that cannot be captured by filter mesh circulate Filter clogging Frequency of filter replacement (forgetting) Re-release of microparticle contaminants
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The machine oil used in hydraulic and lubrication systems is constantly battling contamination. The wear particles that are always generated can lead to catastrophic mechanical damage, such as galling, wear chains, and valve blockages, which is why filters are always installed to prevent these issues. So why do failures still occur due to fluid cleanliness despite the presence of standard filters? It is because even extremely small wear particles, which cannot be captured by regular filters, still affect the wear and damage of equipment. This type of filter is designed to capture particles larger than the pores (voids) of the element itself. In other words, particles smaller than the filter's pores tend to pass through unobstructed. However, if the filter is made finer to actively filter out fine particles, it will quickly become clogged, necessitating frequent replacements. If replacements are not made, the safety valve will open to prevent blockage in the flow path, rendering the filter ineffective. Therefore, the only option is to accept the presence of fine particles and use a filter that only captures particles within a range that does not immediately lead to failure. If one forgets to replace a saturated filter, damage will occur.
Line up（5）
| Model number | overview |
|---|---|
| Clear Series (for low-pressure general liquids) | ・Features Model for aqueous solutions Transparent housing Easy maintenance with T-type design High-capacity integrated model As a final filter for cutting fluids For scale removal in cooling water such as chillers ・Applications Machine processing cutting fluids Cooling fluids Cleaning fluids (caution regarding resin resistance for hydrocarbon-based solutions) |
| Model CP (for hydraulic circuits) | ・Features Compact model that can be directly installed in hydraulic circuits Housing that can withstand high pressure Upstream of important components in hydraulic circuits Model CP photo ・Applications Hydraulic lines Small transmissions Engine fuel lines |
| Model M (for hydraulic devices) | Versatile model High capture capacity Balances pressure loss and capture efficiency Simple and compact Model M photo ・Applications Main piping for hydraulic devices Medium transmissions Engine various lines |
| Process Unit (large models for lubricating oil, etc.) | Large diameter and high-capacity model Compatible with high flow piping Ensures protection for critical centralized systems such as power generation systems Maximum preventive maintenance Process Unit photo ・Applications Main piping for large hydraulic devices Large transmissions |
| Suction Filter Type | ・Features Serves as a suction filter inside the tank of hydraulic devices Effectively captures iron powder particles down to 0.07 microns Model designed to protect pumps from clogging A significant protective solution for hydraulic devices Pump Mate photo ・Applications Suction line for hydraulic devices |
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