Dry-Sump Pump Module Gas Separation
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Solution Overview
Problem
Off-road vehicle internal combustion engines face challenges in optimal lubrication due to high-powered operation and unique conditions, including difficulty in implementing gas separation systems and efficiently routing gases within the engine, as well as complex configurations of the pump module in the lubrication system.
Innovation Solution
The internal combustion engine design includes a dry-sump lubrication system with a pre-assembled pump module that comprises pressure and scavenge pumps, static housing members, and an outer flange for secure installation, along with a cyclonic separator to manage gas content in the oil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gas separation system is implemented to extract gas content from the oil, then the reliability of the pump module is improved, but the device complexity increases and the ease of manufacture deteriorates
Solution Approach 1:
The gas separation system is nested within the existing oil tank structure. The oil tank is configured to receive oil from the engine and separate gas content from the oil while containing the oil, eliminating the need for a separate external gas separation system and reducing overall device complexity.
Solution Approach 2:
The oil tank performs multiple functions: it stores oil, separates gas from oil, and conditions the oil before it enters the pump module. By combining these functions in a single component, the system reduces the number of separate parts while maintaining reliability.
2Reliability
If a gas separation system is implemented, then the reliability of the pump module is improved, but the ease of operation deteriorates due to difficult gas routing
Solution Approach 1:
The gas separation function is merged with the oil storage function in the oil tank. Gas separates from oil within the tank structure itself, and the separated gas can be routed through existing engine pathways, simplifying the overall gas routing operation.
3Reliability
If a complex pump module configuration is used to ensure proper oil circulation, then the reliability of lubrication is improved, but the ease of manufacture deteriorates
Solution Approach 1:
The pump module is segmented into distinct pressure pumps and scavenge pumps, each with specific functions. This segmentation allows for standardized manufacturing of individual pump units while maintaining the complex multi-pump configuration needed for reliable lubrication under various operating conditions.
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 design enhances lubrication efficiency by effectively circulating oil and managing gas content, reducing the risk of damage to the pump module and ensuring reliable operation under demanding conditions.
Implementation Method 1
a cyclonic separator to manage gas content in the oil
Implementation Method 2
at least one pressure pump mounted to the pump shaft and configured to pump oil from the oil tank
Implementation Method 3
at least one scavenge pump mounted to the pump shaft and configured to draw oil from a respective part of the engine
Data Source
AI summary
An internal combustion engine for a vehicle and a method for assembling an internal combustion engine. The engine includes a crankcase; a crankshaft disposed at least in part in the crankcase; a cylinder block connected to the crankcase, the cylinder block defining at least one cylinder; at least one piston operatively connected to the crankshaft and disposed in a corresponding cylinder; an oil tank defining an oil reservoir configured to contain oil therein; and a dry-sump lubrication system comprising a pump module for circulating oil throughout the engine. The pump module includes a pump shaft rotatable about a pump shaft axis; at least one pressure pump mounted to the pump shaft and configured to pump oil from the oil tank; and at least one scavenge pump mounted to the pump shaft and configured to draw oil from a respective part of the engine.