Electrostatic Purge Exhaust Processor for Air Brake Systems
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Solution Overview
Problem
Compressed air regenerative dryers on air-braked vehicles expel water mixed with oil to the atmosphere during purge cycles, leading to environmental concerns and premature component replacements due to oil accumulation, as existing separators are bulky and unsuitable for motor vehicles.
Innovation Solution
A purge exhaust processor with an inlet chamber, a sump chamber, and an electrostatically charged surface that agglomerates oil and water aerosols into liquid, allowing them to be collected in the sump chamber via an orifice, with a drain system to redirect the liquid to the compressor's oil reservoir.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If compressed air condensate management separators (baffles and coalescing elements) are used to separate oil and water from condensate, then separation effectiveness is improved, but device size becomes bulky and unsuitable for motor vehicles
Solution Approach 1:
The patent replaces traditional mechanical separation systems (baffles and coalescing elements) with an electrostatic precipitation system. A high-voltage electrode generates an electrostatic field that charges oil and water aerosol particles, causing them to migrate to and deposit on a grounded collector surface. This substitution achieves effective separation while dramatically reducing the device size, making it suitable for motor vehicle applications.
2Duration of action of stationary object
If oil is expelled to atmosphere during purge cycles, then the air dryer can be regenerated, but environmental pollution occurs and oil accumulates around the purge exhaust valve
Solution Approach 1:
The patent converts the harmful effect of oil aerosol expulsion into a beneficial separation process. The electrostatic precipitation system captures oil and water particles that would otherwise be expelled to atmosphere, redirecting them to a collection reservoir. This allows the air dryer to be regenerated through purging while preventing environmental pollution and oil accumulation around the purge exhaust valve.
3Productivity
If oil accumulates around the purge exhaust valve, then the purge cycle can continue, but premature wear is perceived and unnecessary replacements occur
Solution Approach 1:
The patent extracts oil and water aerosols from the purge exhaust stream before they can accumulate around the purge exhaust valve. The electrostatic precipitation system removes these contaminants and directs them to a collection reservoir, preventing oil buildup that would otherwise lead to premature wear perception and unnecessary component replacements.
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
Effectively reduces oil expulsion to the atmosphere, preventing premature component replacements and environmental issues by efficiently separating and collecting oil and water from the purge exhaust, suitable for use on motor vehicles.
Implementation Method 1
The selectively charged surface agglomerates at least one of the oil aerosol and water aerosol into a liquid
Data Source
AI summary
A purge exhaust processor includes an inlet chamber, a sump chamber, a selectively charged surface in the inlet chamber, and an orifice. The inlet chamber receives purge exhaust including at least one of air, water vapor, oil aerosol, and water aerosol. The selectively charged surface agglomerates at least one of the oil aerosol and water aerosol into a liquid. The orifice is sized for passing the agglomerated liquid from the inlet chamber to the sump chamber.