An integrated crankcase breather for a high speed diesel engine and a method of operation thereof

Abstract

The application discloses an integrated type crankcase breather for a high-speed diesel engine and a working method thereof, and belongs to the field of diesel engine breathers. The integrated type crankcase breather comprises a breather plate assembly arranged in a valve chamber cover, a labyrinth structure arranged in the valve chamber cover, a gas exhaust valve structure arranged at the top end of the valve chamber cover, and a waste gas outlet arranged on the right side wall of the valve chamber cover body. The breather plate assembly comprises a bottom plate, a waste gas inlet arranged at the lower end of the bottom plate, a flow guide plate arranged at the upper end of the bottom plate and communicated with the waste gas inlet, a gas blocking plate arranged at the upper end of the flow guide plate, a first impact plate arranged at the right side of the gas blocking plate, and a second impact plate arranged at the right side of the first impact plate. An oil return port is further arranged at the left end of the bottom plate. The gas exhaust valve structure comprises a cover plate, a rubber diaphragm and a spring. The breather is integrated in the diesel engine valve chamber cover, the requirement of diesel engine waste gas filtration is met, the fault risk of the diesel engine is reduced, and the compactness and reliability of the diesel engine are improved.

Description

Technical Field

[0001] This invention relates to the field of diesel engine breather technology, and in particular to an integrated crankcase breather for high-speed diesel engines and its working method. Background Technology

[0002] When a diesel engine is running, a small amount of high-pressure combustible mixture and burned gas from the combustion chamber leaks into the crankcase through the gap between the piston assembly and the cylinder, causing blow-by. Blow-by consists of unburned fuel gas, water vapor, and exhaust gases, which dilute the engine oil's performance and accelerate its oxidation and deterioration. Water vapor condenses in the engine oil, forming sludge and clogging oil passages; acidic gases in the blow-by mix with the lubrication system, leading to corrosion and accelerated wear of engine parts; blow-by can also cause excessive pressure in the crankcase, compromising its seal and causing oil leakage. Furthermore, some crankcase components are lubricated by splash lubrication; the oil mist generated by splash lubrication mixes with the high-temperature blow-by gas from the cylinder, forming extremely fine aerosol particles, which are the main components of crankcase exhaust gases. Direct emission of these exhaust gases into the atmosphere not only causes significant oil loss but also greatly pollutes the environment and affects emission standards. If exhaust gas is fed into the diesel engine's intake manifold for secondary combustion, the presence of a large amount of engine oil in the exhaust gas can cause the diesel engine to burn oil. Therefore, diesel engine crankcases are equipped with ventilation devices. This invention is used on the diesel engine crankcase to discharge exhaust gas, regulate the pressure within the crankcase within a suitable range, and separate and recover the engine oil components in the exhaust gas, allowing excess engine oil to flow back to the oil pan and clean exhaust gas to exit the crankcase. Similar technical solutions include natural ventilation, labyrinth ventilation, cyclone ventilation, filter ventilation, and impact ventilation. These solutions are mostly external components, independent of the diesel engine body, attached to the external auxiliary brackets of the diesel engine. This may result in an excessively large overall size of the diesel engine, complex external piping, and excessively long connecting pipes that can increase the pressure difference before and after the breather, causing excessive crankcase pressure and leading to oil leaks from crankcase oil seals.

[0003] Existing diesel engine crankcase breathers, such as natural ventilation type, labyrinth type, cyclone type, filter type, and impact type, are mostly independent components installed in a suitable position on the diesel engine via external auxiliary fixing brackets. These have the following disadvantages: First, external breathers affect the overall dimensions of the diesel engine, reducing its structural compactness. Second, external breathers require the design of crankcase exhaust gas connection pipes, which also reduces the engine's structural compactness; furthermore, due to engine vibration, pipe malfunctions can significantly reduce engine reliability. Third, crankcase exhaust gas connection pipes increase the pressure difference before and after the breather, causing excessive crankcase pressure and potentially leading to crankcase oil seal leaks. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide an integrated crankcase breather for a high-speed diesel engine and its working method. By integrating the breather into the valve cover of the diesel engine, the requirements for diesel engine exhaust gas filtration are not only met, but the structural compactness of the diesel engine is also greatly improved. Furthermore, the number of crankcase exhaust gas connection pipes is reduced, the risk of diesel engine failure is reduced, and the reliability of the diesel engine is improved.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0006] An integrated crankcase breather for a high-speed diesel engine includes a breather plate assembly disposed within the valve cover, a labyrinth structure disposed within the valve cover, a bleed valve structure disposed at the top of the valve cover, and an exhaust outlet disposed on the right side wall of the valve cover body. The breather plate assembly includes a base plate, an exhaust inlet disposed at the lower end of the base plate, a guide plate disposed at the upper end of the base plate and communicating with the exhaust inlet, a baffle plate disposed at the upper end of the guide plate, a first impact plate disposed to the right of the baffle plate, and a second impact plate disposed to the right of the first impact plate. An oil return port is also disposed at the left end of the base plate. The labyrinth structure includes a first baffle connected to the top of the valve cover body, a second baffle connected to the right side wall of the valve cover body, and a third baffle perpendicularly disposed on the second baffle. The left side of the first baffle and the right side of the first impact plate form an upper guide space. The bleed valve structure includes a cover plate, a rubber diaphragm, and a spring.

[0007] A further improvement of the technical solution of the present invention is that: both the first impact plate and the second impact plate are inverted U-shaped perforated plates.

[0008] A further improvement of the technical solution of the present invention is that: the U-shaped height of the second impact plate is less than the U-shaped height of the first impact plate; and the U-shaped width of the second impact plate is greater than the U-shaped width of the first impact plate.

[0009] A further improvement of the technical solution of the present invention is that: no holes are provided on the upright plate on the side adjacent to the first impact plate and the second impact plate, and holes are provided on the upright plate on the side adjacent to the first impact plate and the air barrier plate.

[0010] A further improvement of the technical solution of the present invention is that: no holes are provided on the side plate of the second impact plate adjacent to the first impact plate, and holes are provided on the side plate of the second impact plate adjacent to the right side wall of the valve cover body.

[0011] A further improvement of the technical solution of the present invention is that the exhaust gas outlet is located at the upper end of the second baffle.

[0012] A further improvement of the technical solution of the present invention is that the bottom end of the first baffle is located at the upper left side of the second impact plate.

[0013] A further improvement of the technical solution of the present invention is that the included angle α between the first impact plate and the bottom plate is 93°.

[0014] A further improvement of the technical solution of the present invention is that: the air baffle is positioned directly above the guide plate at a distance; the air baffle has an open structure around its perimeter.

[0015] A method for operating an integrated crankcase breather for a high-speed diesel engine: When the diesel engine is running, exhaust gas from the crankcase enters the breather through the cylinder head valve chamber space via the exhaust gas inlet, a guide plate, and a baffle plate. The exhaust gas velocity is reduced and its direction of flow is changed, causing it to diffuse outwards. It then passes the first impact plate, where the exhaust gas velocity is further reduced, and larger oil droplets in the exhaust gas are collided and adsorbed, while the exhaust gas direction is also changed. The exhaust gas is then guided through the upper guide space to the second impact plate, where the exhaust gas velocity is reduced again, and smaller oil droplets are collided and adsorbed. Finally, the exhaust gas rises, bypasses the rubber diaphragm and spring, and exits the crankcase through the exhaust gas outlet. The oil droplets adsorbed on the first and second impact plates flow back to the diesel engine oil pan through the oil return port under gravity, ending the process.

[0016] The rubber diaphragm is connected to the atmosphere above the cover plate. When the exhaust gas pressure in the crankcase is lower than atmospheric pressure by 800 Pa, the atmospheric pressure compresses the spring through the rubber diaphragm, sealing the exhaust gas outlet channel and preventing further exhaust gas discharge, thus ensuring pressure balance inside the crankcase.

[0017] The technological advancements achieved by this invention due to the adoption of the above technical solutions are as follows:

[0018] This invention combines labyrinthine and impact-type filtration methods, integrating a breather assembly comprising a guide plate, a baffle plate, a first impact plate, an exhaust inlet, a base plate, and a second impact plate into the valve cover. The valve cover also includes a guide space, a cover plate, a rubber diaphragm, a spring, and an exhaust outlet. By integrating the breather into the diesel engine valve cover, it not only meets the diesel engine exhaust filtration requirements but also reduces the need for external breather piping connections, significantly improving the diesel engine's structural compactness. Furthermore, the reduced crankcase exhaust connection pipe lowers the risk of diesel engine failure and enhances the engine's economy and reliability. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram illustrating the structural principle of the integrated crankcase breather for high-speed diesel engines provided in this embodiment of the invention.

[0021] Figure 2 This is a top view of the respirator plate assembly in an embodiment of the present invention;

[0022] Figure 3 This is a side view of the respirator plate assembly in an embodiment of the present invention;

[0023] Figure 4 This is a perspective view of the respirator plate assembly in an embodiment of the present invention;

[0024] The components include: 1. Valve cover; 1-1. First baffle; 1-2. Second baffle; 1-3. Third baffle; 2. Deflector; 3. Air baffle; 4. First impact plate; 5. Upper guide space; 6. Cover plate; 7. Rubber diaphragm; 8. Spring; 9. Exhaust outlet; 10. Second impact plate; 11. Base plate; 11-1. Bolt hole; 12. Exhaust inlet; 13. Oil return port. Detailed Implementation

[0025] It should be noted that the terms "comprising" and "having" and any variations thereof in the specification, claims and accompanying drawings of this invention are intended to cover non-exclusive inclusion. For example, a process, method, system, product or device that includes a series of steps or units is not necessarily limited to those steps or units that are explicitly listed, but may include other steps or units that are not explicitly listed or that are inherent to such processes, methods, products or devices.

[0026] Furthermore, in the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0027] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0028] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments:

[0029] High-speed diesel engines are V-type 8-cylinder structures with four cylinders on each side. During operation, a small amount of high-pressure combustible mixture and burned-out gas from the combustion chamber leaks into the crankcase through the gap between the piston assembly and the cylinders, causing blow-by. Since some components in the crankcase use splash lubrication, when the oil mist generated by splash lubrication and the oil vapor evaporated at high temperatures mix with the blow-by gas, they form extremely fine aerosols with most particles smaller than 1μm. This is the main component of crankcase exhaust gas. To achieve diesel engine exhaust gas filtration, reduce the piping connections of external breather, improve the structural compactness of the diesel engine, reduce the risk of engine failure, and improve the economy and reliability of the diesel engine, the inventors of this application have integrated a breather plate assembly into one of the valve cover units in each of the four cylinders on each side, added a labyrinthine structure to the valve cover, and installed a vent valve structure at the top of the valve cover. This integrates the breather into the diesel engine valve cover, with two integrated crankcase breathers per high-speed diesel engine, achieving the above functions. The specific structure is as follows:

[0030] like Figure 1-4 As shown, an integrated crankcase breather for a high-speed diesel engine includes a breather plate assembly disposed within a valve cover 1, a labyrinth structure disposed within the valve cover 1, a vent valve structure disposed at the top of the valve cover 1, and an exhaust outlet 9 disposed on the right side wall of the valve cover 1 body. The breather plate assembly includes a base plate 11, an exhaust inlet 12 disposed at the lower end of the base plate, a guide plate 2 disposed at the upper end of the base plate 11 and communicating with the exhaust inlet 12, a baffle plate 3 disposed at the upper end of the guide plate 3, and a baffle plate 3 disposed at the baffle plate 3. The first impact plate 4 on the right side and the second impact plate 10 located to the right of the first impact plate 3; the left end of the base plate 11 is also provided with an oil return port 13; the labyrinth structure includes a first baffle 1-1 connected to the top of the valve cover 1 body, a second baffle 1-2 connected to the right side wall of the valve cover 1 body, and a third baffle 1-3 vertically arranged on the second baffle 1-2; the left side of the first baffle and the right side of the first impact plate 3 form an upper guide space 5; the vent valve structure includes a cover plate 6, a rubber diaphragm 7, and a spring 8.

[0031] Furthermore, both the first impact plate 3 and the second impact plate 10 are inverted U-shaped perforated plates.

[0032] Furthermore, the U-shaped height of the second impact plate 10 is less than the U-shaped height of the first impact plate 3; the U-shaped width of the second impact plate 10 is greater than the U-shaped width of the first impact plate 3.

[0033] Furthermore, such as Figure 4As shown, there are no holes on the side of the first impact plate 3 adjacent to the second impact plate 10, but there are holes on the side of the first impact plate 3 adjacent to the air baffle plate 3.

[0034] Furthermore, such as Figure 4 As shown, the second impact plate 10 has no holes on the side of the vertical plate adjacent to the first impact plate 3, while the second impact plate 10 has holes on the side of the vertical plate adjacent to the right side wall of the valve cover 1 body.

[0035] Furthermore, the exhaust gas outlet 9 is located at the upper end of the second baffle 1-2.

[0036] Furthermore, the bottom end of the first baffle 1-1 is located at the upper left side of the second impact plate 10.

[0037] Furthermore, the included angle α between the first impact plate 3 and the base plate 11 is 93°. The base plate 11 has an irregular shape that is wider at the top and narrower at the bottom, and is provided with a plurality of bolt holes 11-1 for mounting and fixing bolts.

[0038] Furthermore, the air baffle 3 is positioned directly above the guide plate 2 at a distance; the air baffle 3 has an open structure on all sides. The airflow passes through the guide plate 2 and blows directly onto the air baffle 3 to slow down the airflow speed.

[0039] A method for operating an integrated crankcase breather for high-speed diesel engines:

[0040] When the diesel engine is running, exhaust gas from the crankcase enters the breather through the exhaust gas inlet via the cylinder head valve chamber and other spaces, passing through the guide plate 2. It then passes through the baffle plate 3, which reduces the exhaust gas velocity and changes its flow direction, causing it to diffuse outwards. Next, it passes through the first impact plate 4, where the exhaust gas velocity is further reduced, and larger oil droplets in the exhaust gas are collided and adsorbed, further changing the exhaust gas flow direction. The exhaust gas is then guided through the upper guide space 5 to the second impact plate 10, where the exhaust gas velocity is reduced again, and smaller oil droplets are collided and adsorbed onto the second impact plate 10. Finally, the exhaust gas rises, bypassing the rubber diaphragm 7 and spring 8, and exits the crankcase through the exhaust gas outlet 9. The oil droplets adsorbed on the first impact plate 3 and the second impact plate 10 flow back to the diesel engine oil pan through the oil return port 13 under gravity, ending the process. The rubber diaphragm 7 is connected to the atmosphere above the cover plate 6. When the exhaust gas pressure in the crankcase is lower than atmospheric pressure by 800Pa, the atmospheric pressure compresses the spring 8 through the rubber diaphragm 7, sealing the exhaust gas outlet 9 channel, and the exhaust gas is no longer discharged, thus ensuring the pressure balance inside the crankcase.

[0041] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. An integrated crankcase breather for a high-speed diesel engine, characterized in that: The system includes a breather plate assembly disposed within the valve cover (1), a labyrinth structure disposed within the valve cover (1), a vent valve structure disposed at the top of the valve cover (1), and an exhaust outlet (9) disposed on the right side wall of the valve cover (1) body; the breather plate assembly includes a base plate (11), an exhaust inlet (12) disposed at the lower end of the base plate, a guide plate (2) disposed at the upper end of the base plate (11) and communicating with the exhaust inlet (12), a baffle plate (3) disposed at the upper end of the guide plate, a first impact plate (4) disposed on the right side of the baffle plate (3), and a first impact plate (4) disposed on the right side of the first impact plate (3). A second impact plate (10) is provided on the right side of the first impact plate (4); an oil return port (13) is also provided on the left end of the base plate (11); the labyrinth structure includes a first baffle (1-1) connected to the top of the valve cover (1) body, a second baffle (1-2) connected to the right side wall of the valve cover (1) body, and a third baffle (1-3) vertically arranged on the second baffle (1-2); the left side of the first baffle and the right side of the first impact plate (4) form an upper guide space (5); the vent valve structure includes a cover plate (6), a rubber diaphragm (7), and a spring (8); Both the first impact plate (4) and the second impact plate (10) are inverted U-shaped perforated plates; the U-shaped height of the second impact plate (10) is less than the U-shaped height of the first impact plate (4); the U-shaped width of the second impact plate (10) is greater than the U-shaped width of the first impact plate (4).

2. An integrated crankcase breather for a high-speed diesel engine according to claim 1, characterized in that: No holes are provided on the side of the first impact plate (4) adjacent to the second impact plate (10), but holes are provided on the side of the first impact plate (4) adjacent to the air barrier plate (3).

3. An integrated crankcase breather for a high-speed diesel engine according to claim 1, characterized in that: The second impact plate (10) has no holes on the side plate adjacent to the first impact plate (4), and the second impact plate (10) has holes on the side plate adjacent to the right side wall of the valve cover (1) body.

4. An integrated crankcase breather for a high-speed diesel engine according to claim 1, characterized in that: The exhaust gas outlet (9) is located at the upper end of the second baffle (1-2).

5. An integrated crankcase breather for a high-speed diesel engine according to claim 1, characterized in that: The bottom end of the first baffle (1-1) is located at the upper left side of the second impact plate (10).

6. An integrated crankcase breather for a high-speed diesel engine according to claim 1, characterized in that: The included angle α between the first impact plate (4) and the base plate (11) is 93°.

7. An integrated crankcase breather for a high-speed diesel engine according to claim 1, characterized in that: The air baffle (3) is positioned directly above the guide plate (2) at a distance; the air baffle (3) has an open structure around its perimeter.

8. A method of operating an integrated crankcase breather for a high-speed diesel engine as described in any one of claims 1-7, characterized in that: When the diesel engine is working, the exhaust gas in the crankcase enters the breather through the exhaust gas inlet (12) and guide plate (2) through the cylinder head valve chamber space. After passing through the baffle plate (3), the exhaust gas flow rate is reduced, the exhaust gas flow direction is changed, and it diffuses to the surroundings. Then it passes through the first impact plate (4), at which time the exhaust gas flow rate is further reduced, and the larger oil droplets in the exhaust gas are collided and adsorbed. At the same time, the exhaust gas flow direction is changed. Then the exhaust gas is guided to the second impact plate (10) through the channel of the upper guide space (5). At this time, the exhaust gas flow rate is reduced again, and the smaller oil droplets in the exhaust gas are collided and adsorbed on the second impact plate (10). Then the exhaust gas goes up and bypasses the rubber diaphragm (7) and spring (8) and enters the exhaust gas outlet (9) to be discharged from the crankcase. The oil droplets adsorbed on the first impact plate (4) and the second impact plate (10) flow back to the diesel engine oil pan through the oil return port (13) under the action of gravity, and the working process ends. The rubber diaphragm (7) is connected to the atmosphere above the cover plate (6). When the exhaust gas pressure in the crankcase is lower than the atmospheric pressure by 800 Pa, the atmospheric pressure compresses the spring (8) through the rubber diaphragm (7), sealing the exhaust gas outlet (9) and preventing the exhaust gas from being discharged, thus ensuring the pressure balance inside the crankcase.

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