Modular Crankcase Ventilation with Oil Separation Filters
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Solution Overview
Problem
Internal combustion engines face challenges with crankcase ventilation systems, particularly in large diesel engines with forced induction, where crankcase emissions can foul compressor wheels and cooling units due to the presence of contaminants like hydrocarbons, carbon monoxide, NOx, soot, and unburned fuel, leading to inefficiencies and maintenance issues.
Innovation Solution
A modular crankcase ventilation system with oil separation modules and filters that can be strategically positioned along the engine to efficiently remove blow-by gases, including lubricating oil, through a network of conduits and inlet housings, allowing for flexible placement and incremental capacity adjustment based on engine configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If crankcase emissions are returned to the intake side of a compressor in a supercharger or turbocharger, then the emissions are reused in the combustion process, but the compressor wheel becomes fouled with contaminants
Solution Approach 1:
The patent extracts and removes contaminants (oil aerosols, soot, hydrocarbons) from the crankcase emissions before the gases are returned to the intake system. This is achieved through filtration systems that separate harmful particles from the breathable gas portion, allowing clean gas to be recirculated while contaminants are removed and disposed of separately.
Solution Approach 2:
The patent introduces an intermediary filtration system between the crankcase and the intake system. This intermediary component (oil separator, filter, or purifier) acts as a mediator that allows the beneficial recirculation of crankcase gases while blocking and removing harmful contaminants, thus protecting the compressor wheel from fouling.
2Power
If multiple turbocharger systems are used to enhance power output, then the power output increases, but the heat increases downstream compressor units causing compounded fouling
Solution Approach 1:
The patent applies extraction principles by removing contaminants from crankcase emissions before they enter the intake system of multi-turbocharger configurations. This prevents the accumulation of fouling materials in downstream compressor units, allowing the engine to maintain high power output without proportional increases in maintenance needs.
Solution Approach 2:
The patent segments the crankcase ventilation system into multiple filtration stages or separate treatment paths for different engine configurations. This segmentation allows targeted removal of contaminants that would otherwise accumulate in specific downstream compressor units, enabling each turbocharger to operate cleaner for longer periods.
3Object-affected harmful factors
If a filtered crankcase ventilation system is implemented, then contaminants are removed from emissions, but the system complexity increases
Solution Approach 1:
The patent employs universal filtration components that can serve multiple functions: oil separation, water separation, particle filtration, and gas purification. These multi-functional components reduce overall system complexity by consolidating what could be multiple separate systems into integrated units that handle various contaminant types simultaneously.
Solution Approach 2:
The patent merges oil separation, water separation, and particle filtration functions into integrated crankcase ventilation systems. By combining these functions into single units or closely integrated components, the system achieves effective contaminant removal while minimizing the number of separate parts, connections, and maintenance procedures 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 system effectively removes contaminants from crankcase emissions, preventing fouling of compressor wheels and cooling units, enhancing engine performance and reducing maintenance needs by providing a flexible and efficient ventilation solution adaptable to various engine configurations.
Implementation Method 1
a first oil separation filter disposed in fluid connection between the conduit and the oil pan
Data Source
AI summary
An internal combustion engine includes a crankcase having first and second pluralities of openings. A oil separation module has at least one inlet housing that communicates with a oil separation filter and is connectable to at least one opening from the first plurality of openings or from the second plurality of openings to define a crankcase vent.