Crankcase Separator Thrust Nozzle Drive
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Solution Overview
Problem
Existing separators for oil mist from crankcase ventilation gas in internal combustion engines have inefficiencies in rotary drive systems, leading to high lubrication oil consumption, limited rotor speed, and increased manufacturing costs, as well as large size and low oil mist separation efficiency.
Innovation Solution
A separator design with a base forming the separation between the gas purification and drive chambers, featuring a shaft bearing located away from the centrifugal rotor, and a rotary drive with thrust nozzles that minimizes friction and imbalances, allowing for high-speed operation with reduced lubrication oil consumption and improved oil mist separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If an impeller wheel is used as rotary drive with pressurized lubrication oil sprayed through stationary nozzles, then the centrifugal rotor can be driven, but the efficiency is relatively bad resulting in high lubrication oil consumption and limited rotor speed
Solution Approach 1:
The invention extracts the bearing support function from the base plate and relocates it to a dedicated support structure extending into the drive chamber. This separates the rotational support function from the structural base, allowing the base plate to be optimized for sealing and structural integrity while the support structure optimizes for bearing alignment and rotational efficiency, thereby reducing friction losses and lubrication oil consumption
Solution Approach 2:
The support structure acts as an intermediary element between the base plate and the centrifugal rotor bearing. This intermediate structure provides precise bearing alignment and support while allowing the base plate to maintain its sealing function, reducing friction at the bearing interface and improving overall drive efficiency
2Ease of manufacture
If the base plate is made as a simple sealing element, then manufacturing is easy, but it cannot support the bearing for the shaft
Solution Approach 1:
The invention segments the base plate function into two distinct components: the base plate itself which provides sealing and structural support, and a separate support structure which provides bearing alignment and support. This segmentation allows each component to be optimized independently - the base plate for simple sealing manufacturing while the support structure handles the complex bearing support function
Solution Approach 2:
The support structure serves multiple functions simultaneously: it provides bearing support, ensures proper shaft alignment, and maintains the separation between drive chamber and gas purification chamber. This multi-functionality reduces the need for additional separate components, balancing device complexity with functional requirements
3Loss of energy
If the bearing is located close to the centrifugal rotor, then the structure is compact, but friction and imbalances increase reducing drive efficiency
Solution Approach 1:
The support structure extends into the drive chamber in the axial dimension, creating a three-dimensional arrangement where the bearing is positioned optimally for reduced friction while maintaining compact overall dimensions. This vertical extension allows the bearing to be located away from the base plate without increasing the radial footprint, effectively using the axial dimension to resolve the contradiction
4Quantity of substance
If a lubrication oil centrifuge is used with thrust nozzles, then oil can be separated, but the crankcase ventilation gas is burdened with additional oil load and the separator must be relatively large
Solution Approach 1:
The invention extracts the oil separation function from the lubrication oil centrifuge and relocates it to a dedicated separator unit with its own centrifugal rotor. This separates the oil centrifugation function from the crankcase ventilation gas handling, allowing the separator to be optimized for gas processing while the lubrication oil centrifuge handles oil removal independently, thereby reducing the overall separator size required
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 solution achieves high efficiency in oil mist separation, reducing the risk of oil deposits in engine suction tracts, preventing engine malfunctions, and enabling a compact, cost-effective design with lower manufacturing costs and improved structural integrity.
Implementation Method 1
a rotatably mounted centrifugal rotor is arranged in a gas purification chamber... pure gas liberated from oil mist can be discharged from the gas purification chamber... oil separated from the gas can be discharged from the gas purification chamber
Implementation Method 2
The rotary drive is formed by at least one thrust nozzle which is connected to the shaft and to which the pressurized lubrication oil of the internal combustion engine can be fed
Data Source
AI summary
A separator for separating oil mist from the crankcase ventilation gas of an internal combustion engine, especially of a motor vehicle. The separator includes a gas purification chamber inside which a rotatably mounted centrifugal rotor is arranged. The gas purification chamber has a crude gas inlet, a pure gas outlet, and an oil outlet. The crankcase ventilation gas can be conducted into a radially internal zone of the centrifugal rotor via the crude gas inlet, while pure gas that is liberated from oil mist can be discharged from the gas purification chamber via the pure gas outlet, and oil separated from the gas can be discharged from the gas purification chamber via the oil outlet. The separator further includes a rotary drive for the centrifugal rotor. The rotary drive is disposed in a drive chamber of the separator, can be operated using pressurized lubrication oil of the internal combustion engine, and is connected to the centrifugal rotor by means of a shaft extending from the drive chamber into the gas purification chamber, from which the drive chamber is separated. The rotary drive is formed by at least one thrust nozzle which is connected to the shaft and to which the pressurized lubrication oil of the internal combustion engine can be fed. The separator includes at least one part of a base that forms the separation between the gas purification chamber and the drive chamber and extends into the drive chamber, the part of the base being fitted with a seat for a bearing of the shaft. The bearing is located at a distance from the centrifugal rotor.