Curved Channel Separator for Crankcase Gas Droplet Removal
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Solution Overview
Problem
Existing separators for crankcase ventilation gases in internal combustion engines, particularly those with conical discs, face challenges in separation efficiency for fine droplets, axial length, and sensitivity to gas flow volume changes, leading to suboptimal performance and increased pressure loss.
Innovation Solution
A separator design featuring flat disk bodies with curved channels that allow gas to flow from the inner to the outer radial portion, utilizing centrifugal and Coriolis forces to separate liquid droplets on impact surfaces, optimizing channel geometry for increased separation capacity and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conical discs are used in the separator, then separation efficiency for liquid droplets is improved, but axial length increases
Solution Approach 1:
The patent applies curvature by using curved channels instead of straight channels in the flat discs. The curved channels create centrifugal and Coriolis forces that enhance droplet separation efficiency while maintaining a compact axial structure, resolving the contradiction between separation efficiency and axial length.
Solution Approach 2:
The patent changes the geometric parameters of the channels (curvature radius, channel width, channel height) to optimize the balance between separation efficiency and axial length. By adjusting these parameters, the separator achieves high separation performance in a compact axial space.
2Reliability
If conical discs are used in the separator, then separation efficiency for liquid droplets is improved, but device complexity increases
Solution Approach 1:
The patent divides the separator into multiple flat discs with curved channels, where each disc acts as an independent separation stage. This segmentation allows the complex separation task to be distributed across multiple simpler stages, maintaining high efficiency while managing structural complexity.
Solution Approach 2:
The curved channels in flat discs provide the necessary centrifugal and Coriolis forces for efficient separation without requiring the complex conical geometry, thus reducing device complexity while maintaining separation efficiency.
3Length of moving object
If the number of discs is decreased to reduce axial length, then axial length is reduced, but separation efficiency deteriorates
Solution Approach 1:
The curved channels generate stronger centrifugal and Coriolis forces compared to straight channels, enabling each disc to achieve higher separation efficiency. This allows the use of fewer discs while maintaining overall separation performance, thus reducing axial length without sacrificing efficiency.
Solution Approach 2:
By optimizing channel parameters (curvature radius, width, height) and disc spacing, the patent enhances the separation capability of each individual disc, allowing fewer discs to achieve the required overall separation efficiency with reduced axial length.
4Device complexity
If passive separators are used instead of driven separators, then device complexity is reduced, but separation efficiency for fine droplets deteriorates
Solution Approach 1:
The curved channels in the passive separator create centrifugal and Coriolis forces that effectively separate fine droplets without requiring active driving mechanisms. This maintains low device complexity while achieving high separation efficiency for fine droplets.
Solution Approach 2:
The patent utilizes gas flow dynamics and fluid mechanics principles to generate the necessary forces for separation through the curved channel geometry, eliminating the need for mechanical driving components while maintaining effective fine droplet separation.
5Volume of moving object
If separator size is reduced to save installation space, then installation space is reduced, but separation efficiency for fine droplets deteriorates
Solution Approach 1:
The curved channel geometry maximizes the utilization of available space by creating effective separation forces through compact radial and axial dimensions, enabling high separation efficiency for fine droplets in a reduced overall separator size.
Solution Approach 2:
The patent transitions from axial separation (conical discs) to radial separation (curved channels in flat discs), utilizing the radial dimension more effectively to achieve high separation efficiency in a compact overall size with reduced axial and radial footprints.
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 design achieves higher separation efficiency with reduced axial length, improved handling of fine droplets, and adaptability to varying gas flow conditions, while minimizing pressure loss and enhancing the use of installation space.
Implementation Method 1
liquid droplets carried by the gas to be cleaned are flung against the inner surfaces of the conical discs by centrifugal forces acting upon them
Implementation Method 2
utilizing centrifugal and Coriolis forces to separate liquid droplets on impact surfaces
Implementation Method 3
the separated liquid then flows by gravity into the lower part of the housing and exits through its liquid outlet
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
Separator for separating liquid droplets from an aerosol (crude gas), having a rotor (30) arranged in a housing (10), said rotor having multiple discs parallel to each other (32a-32e), having a gas flow path between a crude gas inlet (18a) of the separator, a clean gas outlet (20a) and an annular space (50) between the periphery of the rotor and the housing, wherein an intermediate space is formed between discs adjacent to each other, the radial outer region of which space opens into the annular space, and wherein with respect to the crude gas inlet and clean gas outlet passages, one communicates with the annular space and the other with radial inner regions of intermediate spaces. To improve the separation capability of such a separator of specified size, the separator is designed such that: the discs have flat disc bodies arranged vertically to the rotor axis; a plurality of adjacent channels (40), through which gas to be cleaned can flow, is provided between respective adjacent disc bodies; each channel extends at least substantially from a radial inner region to a radial outer region of the intermediate space; each channel is curved; the radially outer surface of the channel wall surfaces delimiting the width of the channel on both sides forms an impact and separation surface for the liquid droplets.