Crankcase Oil Separator Radial Redirection Impact Filtration
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Solution Overview
Problem
Existing oil separators for internal combustion engine crankcase ventilation face challenges in achieving high separation power while minimizing gas flow resistance, leading to residual oil in the charge air tract and potential fouling of air mass measuring members and turbochargers.
Innovation Solution
The design incorporates a redirection member within the oil separator that redirects the gas flow radially outward against the inner side of the oil separation member, utilizing a hyperbola-like redirection contour and a funnel-like shape to create an impactor effect, allowing for efficient separation of oil droplets without significant pressure loss, and using a nonwoven material for the oil separation member to enhance separation and filtration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a torsion generator with helical flow channels is used to separate oil from gas flow, then separation capacity is improved, but flow resistance increases substantially
Solution Approach 1:
The oil separation process is divided into two distinct stages: first, a centrifugal separation stage using a centrifugal separator to remove bulk oil droplets, and second, a filtration stage using a filter element to capture residual oil particles. This segmentation allows each component to be optimized for its specific function while maintaining overall low flow resistance.
Solution Approach 2:
The patent extracts the torsion generator (helical flow channels) from the design and replaces it with a centrifugal separator that achieves oil separation through radial outward movement of oil droplets without introducing substantial flow resistance. This extraction removes the harmful element while preserving the separation function.
2Reliability
If the hollow member is formed by a rotating camshaft with torsion, then oil separation is enhanced, but gas flow resistance increases
Solution Approach 1:
The patent converts the potential harm of high flow resistance into a benefit by using a centrifugal separator that leverages the kinetic energy of the incoming gas flow to generate centrifugal force. The straight-through design allows the gas flow's own momentum to perform the separation work without adding resistance.
Solution Approach 2:
The invention uses pneumatic principles by allowing the gas flow itself to drive the separation process through its kinetic energy, creating a centrifugal effect without mechanical torsion. The straight-through centrifugal separator uses fluid dynamics rather than mechanical rotation to achieve separation.
3Productivity
If residual oil is not adequately separated, then combustion efficiency deteriorates, but air mass measuring members and turbochargers become fouled
Solution Approach 1:
The oil removal process is segmented into two stages: bulk separation by the centrifugal separator and fine filtration by the filter element. This ensures that both combustion efficiency is maintained and downstream components are protected from fouling.
Solution Approach 2:
A filter element made of porous material is introduced to capture residual oil particles that pass through the centrifugal separator. The porous structure provides high surface area for filtration while maintaining acceptable flow characteristics, ensuring thorough oil removal.
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
This configuration achieves a high separation power with minimal pressure loss, preventing narrow cross-sections and reducing flow resistance, ensuring efficient oil separation and reduced contamination in the charge air tract.
Implementation Method 1
redirects the gas flow radially outward against the inner side of the oil separation member, utilizing ahyperbola-like redirection contour and a funnel-like shape to create an impactor effect
Implementation Method 2
using a nonwoven material for the oil separation member to enhance separation and filtration
Data Source
AI summary
An oil separator may be used in a variety of contexts, one of which is for crankcase ventilation of an internal combustion engine. The oil separator may include a hollow member that extends along a longitudinal axis and is configured to receive a gas flow that is charged with oil. The oil separator may also include an oil separation member disposed within the hollow member and against which the gas flow flows. A redirection member may be disposed proximate the oil separation member in the hollow member, wherein the redirection member redirects at least a portion of the gas flow traveling substantially along the longitudinal axis radially outwards so as to impact an inner side of the oil separation member. As a result of an impactor effect from the gas flow striking the oil separation member as well as the inertia of the oil, the oil may remain in and/or pass through the oil separation member.