What needs to be verified for the ULPA prototype? Performance, interface and installation testing

Non-standardULPA filter prototype verification should cover filtration performance, installation interface and actual installed performance. Getting the shape of the prototype right is just the starting point. Manufacturability and consistency of repeated assembly need to be confirmed before mass production. The significance of prototype verification is not to 'make a usable sample', but to confirm whether the configuration represented by this sample can be stably mass-produced and installed and used repeatedly. If the verification scope only covers appearance and filtration performance, poor assembly consistency, seal batch fluctuations, or accumulation of interface tolerances may be found during mass production. Aili Industry isIn the non-standard ULPA filter project, prototype verification is used as a confirmation step before mass production. Performance, interfaces and manufacturability are checked together at the prototype stage. Configurations that pass the verification are then entered into mass production.

1. Freeze the verification input: drawings, materials and working conditions are determined before verification

Document differences between prototypes and planned batch configurations using confirmed versions of drawings, bill of materials, airflow, ratings, and sealing requirements.

The prerequisite for prototype verification is that the input conditions are stable. If the drawings are still being modified and materials are being changed during the verification process, the verification results will not be representative of the final product. Aili Industry isIn the HEPA/ULPA filter prototype project, the drawing version, material list, target air volume, efficiency level and sealing requirements are first frozen and confirmed. The prototype is produced according to the conditions after freezing; if changes are necessary during the verification process, the changes are recorded separately, and the verification results correspond to the changed version. The relationship between levels and filtering requirements can be found inISO cleanliness level comparison。

2. Completion of testing in layers: single unit performance, installation interface and installed performance are verified separately

First check the size, appearance and agreed performance, then try out the installation to check the air volume, pressure difference, uniformity and installation leak detection, and verify the process area if necessary.

The unit test verifies the size, efficiency and resistance of the filter element itself; the interface test verifies the fit of the sample with the box, keel or installation structure; the installation test verifies the air volume, pressure difference, uniformity and sealing status after being installed into the system. The objects of testing at the three levels are different, and problems at any level need to be dealt with back to the corresponding link. Aili Industry isDuring the verification of the ULPA ultra-high efficiency filter prototype, the test results are recorded by level, and the single performance data andFFU fan filter unit orThe installation test data of the fan filter unit on the EFU equipment side is archived separately to facilitate locating the source of the problem. For information on layered verification, please refer toHEPA FAQs and Selection Guide。

3. Feedback problems to the design: drawings need to be changed for interference, tool space and test occlusion

Record interference, tool space, maintenance and test occlusion, and identify which items need to be re-inspected after revising the drawing. Approved prototypes should be traceable to version.

The most valuable problems discovered during the prototype stage are those that will appear repeatedly in mass production. For example, interference with the equipment structure during installation, insufficient tool operating space during replacement, and leak detection probes being blocked by the structure. If these problems are only temporarily solved on the prototype, they will still reappear during mass production. Aili Industrial records the specific locations and handling methods of such problems during prototype verification. If the drawings need to be modified, they will be revised according to the change process. After the revision, it will be clear which verification items need to be redone, and the approved prototypes will be archived correspondingly with the drawing versions. For how to handle interface issues, please refer toULPA ultra-high efficiency filter FAQ and selection guide。

4. During the trial assembly of the sample, a gasket is temporarily added to seal it. The interface problem should be modified into the design.

During the trial assembly of the sample, a gasket is temporarily added to seal it. The interface problem should be modified into the design, and the appearance of the sample cannot be approved only. The temporary addition of a gasket indicates that there is a deviation in the size of the interface or the position of the sealing surface. If this trial assembly is just 'make do', the same problem will occur repeatedly in batch products.

Aili Industry isDuring the verification of non-standard ULPA filter prototypes , for situations that require temporary processing to pass assembly, the design of the interface size or sealing structure will be traced back to the design link for correction, and the corrected drawings will be re-verified, instead of taking 'the sample can be installed' as the passing criterion.Sealing structures such as liquid tank seals, ULPA filters , etc. have high requirements for interface accuracy. The sealing coordination problem in the prototype stage should be solved in the design process. For the relationship between sealing structure and prototype verification, please refer toHEPA FAQs and Selection Guide。

5. Related questions and answers

Can batch testing be saved if the prototype passes?
No, mass production delivery should still implement corresponding inspection and traceability requirements in accordance with the agreement.

Is it enough to only verify the appearance and size of the prototype?
not enough. It should also cover the filtration performance, installation interface coordination, air volume and sealing status after installation.

During the trial installation, a temporary gasket is required to seal it. How to deal with it?
The design problems of the interface size or sealing structure should be traced, and the drawings should be corrected and re-verified. The ability to install the sample should not be used as a passing criterion.

6. Related articles

ULPA ultra-high efficiency filter FAQ and selection guide

Non-standard customized ULPA ultra-high efficiency filter

Liquid tank seal ULPA ultra high efficiency filter

HEPA FAQs and Selection Guide

7. Key points for selection and acceptance inspection

8. Product matching and technical support from Aili Industrial

Aili Industry isIn the non-standard ULPA filter project, prototype verification is used as a confirmation step before mass production. Performance, interfaces and manufacturability are checked together at the prototype stage. Configurations that pass the verification are then entered into mass production. The prototype project is first frozen to confirm the drawing version, material list, target air volume, efficiency level and sealing requirements.HEPA/ULPA filter prototype is made according to freezing conditions;The ULPA ultra-high-efficiency filter prototype is verified hierarchically based on single unit performance, interface coordination, and installed performance. Single unit data andFFU fan filter unit orThe installation data of the fan filter unit at the EFU equipment end is archived separately. The specific locations of interference, tool space and test occlusion problems discovered during the prototype stage are recorded, the drawings are revised according to the change process and re-inspection items are clarified, and the prototype is approved and filed accordingly with the drawing version; the situation where a temporary gasket can be used for sealing can be traced back to the design revision of the interface size or sealing structure.Sealing structures such as liquid tank seals, ULPA filters and other sealing structures have high requirements on interface accuracy, which should be addressed first during the prototype stage. Provide process objectives, installation drawings, operating conditions and acceptance requirements, and can further communicate ULPA standard specifications, non-standard interfaces, samples and batch matching. The specific parameters and test range are based on the confirmed model and technical documents.