Rotary Separator with Dynamic Partition for Crankcase Oil-Gas Separation
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Solution Overview
Problem
Existing rotary separators for filtering blow-by mixtures in crankcases face issues such as clogging at low engine revolutions, limited separation efficiency, and inability to create excessive pressure drop, leading to incomplete separation of oil from gases, which can cause critical engine components to fail.
Innovation Solution
A rotary separator with a dual-function rotary system that includes radial blading for centrifugal acceleration and impact systems with nozzles to separate oil particles from gases, utilizing a positive pressure gradient to enhance separation efficiency and prevent clogging, allowing for installation in various orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rotary filter with centrifugal force is used to separate oil from blow-by mixture, then separation efficiency is improved (exceeding 90%), but the filtering medium becomes clogged at low engine revolutions because centrifugal force is insufficient for self-cleaning
Solution Approach 1:
The patent introduces a movable partition wall that dynamically changes the flow path of the blow-by mixture. At low engine revolutions, the partition wall redirects the flow to maintain sufficient centrifugal force for self-cleaning, preventing clogging of the filtering medium while preserving high separation efficiency across different operating conditions
2Reliability
If pressure drop is increased to improve separation efficiency, then oil droplet separation is enhanced, but the pressure drop cannot be excessive because it limits the average separation capacity and can cause critical component breakage
Solution Approach 1:
The movable partition wall dynamically adjusts the flow path to optimize pressure drop characteristics. It allows the system to achieve high separation efficiency without excessive pressure drop by redirecting flow to maintain appropriate pressure gradients, preventing both insufficient separation and harmful pressure spikes that could damage components
3Device complexity
If alternative separation systems (labyrinth, cyclone, impactor) are used, then device complexity is reduced, but separation efficiency is limited (below 80%) because they rely on flow deflection and pressure drop that cannot be excessively adjusted
Solution Approach 1:
The patent combines the simplicity of alternative systems with the high efficiency of rotary filters by introducing a movable partition wall that dynamically optimizes flow paths. This allows the system to achieve separation efficiency exceeding 90% while maintaining relatively simple structure, as the dynamic partition provides flow control without requiring complex multi-stage separation mechanisms
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 significantly improves separation efficiency, prevents clogging, and allows for effective oil discharge even at low engine speeds, adapting to different engine sizes and rotational speeds, while maintaining a robust and cost-effective design.
Implementation Method 1
a radial blading (27) for a centrifugal fan that sucks the gas mixture from the suction opening (23/24) and sends it to the outlet openings (20)
Implementation Method 2
providing, by means of said radial blading (27), an impact system along which the sucked gas mixture flows and the oil particles present in the mixture impact against walls defining the path
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A rotary separator (1) for filtering the gas mixture present in the crankcase, comprising a casing (3) provided with at least one gas suction opening (23, 24) and a plurality of oil outlet side openings (20) and defining a chamber (4) that houses a rotary system (25) which is shaped to define a plurality of paths (P) which extend from the gas suction opening (23, 24) to the oil outlet openings (20). The rotary system (25) is configured to carry out a dual function: a) providing a radial blading (27) for a centrifugal fan that sucks the gas mixture from the suction opening (23, 24) and sends it to the outlet openings (22); and b) providing, by means of said radial blading (27), an impact system along which the sucked gas mixture flows and the oil particles present in the mixture impact against walls defining the path and are pushed by the centrifugal force towards the oil outlet openings (20) so as to be released outside the rotary separator (1).