Crankcase Ventilation Oil Separation with Disc Stack and Filter
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing crankcase ventilation systems fail to effectively separate oil particles from crankcase blow-by gases, leading to emissions and potential engine inefficiencies, and existing filters require frequent maintenance.
Innovation Solution
A crankcase ventilation system combining a disc stack separator and a filter element, where the disc stack separator removes larger oil particles before they reach the filter, reducing the filter's load and extending its lifespan, while using a filter with higher retention rates to capture smaller particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If only a filter element is used to separate oil particles from crankcase blow-by gases, then small particles below 0.6 μm can be captured, but the filter requires frequent service and has short lifetime due to high loading capacity requirements
Solution Approach 1:
The separation system is divided into two stages: a disc stack separator for preliminary separation of larger oil particles (above 0.6 μm) and a filter element for capturing smaller particles (below 0.6 μm). This segmentation allows each component to operate within its optimal range, extending the filter's service life by pre-removing the bulk of oil particles before they reach the filter.
2Productivity
If only a disc stack separator is used to separate oil particles, then large particles above 0.6 μm can be removed efficiently, but small particles below 0.6 μm are not adequately separated
Solution Approach 1:
The disc stack separator and filter element are merged into a single integrated system where the disc stack separator handles the bulk separation of larger particles and the filter element captures the remaining smaller particles. This combination achieves comprehensive separation across the entire particle size spectrum, maintaining high productivity for large particles while ensuring adequate filtration for small particles.
3Object-generated harmful factors
If a filter element with high retention rate is used to capture all oil particles, then emission quality is improved, but the loading capacity is exceeded quickly requiring frequent maintenance
Solution Approach 1:
The disc stack separator performs preliminary separation of the majority of oil particles before the gases reach the filter element. This preliminary action reduces the loading on the filter element, allowing it to maintain high retention rates for small particles without being overwhelmed, thereby extending maintenance intervals while preserving emission quality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves near-complete separation of oil particles above 0.6 μm and significantly extends the filter's lifetime, increases its loading capacity, and improves engine performance by recycling clean crankcase gases, reducing emissions and maintenance needs.
Implementation Method 1
The rotor comprises an oil separating element arranged within the chamber and spaced from one or more walls of the chamber, and a shaft configured to rotatably mount the oil separating element. The disc stack separator provides a filtration rate of substantially 100% for particles having a size above 0.6 μm.
Implementation Method 2
The filter element comprises a second gas inlet, a second gas outlet, and a filter arranged between the second gas inlet and the second gas outlet. A filter element has a filtration rate of substantially 100%, regardless of the size of the particles.
Data Source
AI summary
A crankcase ventilation system (1) is provided. The system comprises a housing (10), a disc stack separator (20) arranged within the housing which comprises a chamber (21), and a rotor (22). The rotor comprises an oil separating element (23) arranged within the chamber and spaced from one or more walls of the chamber, a shaft (24) configured to rotatably mount the oil separating element. The disc stack separator further comprises a first gas inlet (41) and a first gas outlet (42). The system further comprises a filter element (30) comprising a second gas inlet (43), a second gas outlet (44), and a filter (31) arranged between the second gas inlet and the second gas outlet. The first gas inlet is configured to be connected to a crankcase blow-by outlet of the ICE, and the first gas outlet is connected to the second gas inlet.