Rotary Separator Filter with Uniform Porous Structure
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Solution Overview
Problem
Existing methods for producing filters for rotary air/oil separators in turbine engines result in non-uniform metal distribution due to random positioning of pores, leading to unbalanced centrifugal inertia forces and varying performance across identical filter elements.
Innovation Solution
A process using electron beam melting to produce filters with a titanium alloy (Ti6-4 Ti-6Al-4V) where a three-dimensional mathematical model defines the porous structure, ensuring uniform distribution and higher specific resistance, balancing centrifugal forces and optimizing filtering efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a polymeric matrix with spheres is used to produce filter elements, then the porous structure can be formed, but the position of pores becomes random and metal distribution becomes non-uniform
Solution Approach 1:
The patent replaces the mechanical assembly method (polymeric matrix with spheres) with an electron beam melting process that directly creates the porous structure through digital modeling, eliminating the need for physical sphere positioning and achieving precise pore placement control
Solution Approach 2:
The invention changes the fundamental parameter of pore position from random (in conventional methods) to precisely controlled through three-dimensional mathematical modeling, where pore positions are determined by mathematical equations rather than physical assembly variations
2Ease of manufacture
If random pore positioning is used in filter elements, then production is simplified, but centrifugal inertia forces become unbalanced during rotor rotation
Solution Approach 1:
The patent changes the pore distribution parameter from random to uniformly distributed according to mathematical equations, ensuring that the filter elements have identical mass distribution and generate balanced centrifugal forces during high-speed rotor rotation
Solution Approach 2:
The invention achieves homogeneity in metal distribution and pore positioning through electron beam melting with mathematical modeling, ensuring all filter elements have identical properties and the rotor operates without vibration or imbalance
3Ease of manufacture
If conventional production methods are used, then manufacturing cost is reduced, but filter elements show varying performance at the same rotation speed
Solution Approach 1:
The patent replaces conventional mechanical assembly methods with electron beam melting and mathematical modeling, achieving precise control over pore positioning and metal distribution that ensures identical performance across all filter elements while maintaining production efficiency
Solution Approach 2:
The invention uses three-dimensional mathematical models to precisely replicate the same pore structure and metal distribution in every filter element, ensuring that each element is an exact copy of the designed configuration and performs identically under the same 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
The process achieves balanced and efficient filtering with precise control over the porous structure, enhancing mechanical strength and separation performance at various turbine engine speeds while reducing material weight and production costs.
Implementation Method 1
a production method using an electron beam to locally melt and/or sinteres subsequent layers of powder
Implementation Method 2
a production method using an electron beam to locally melt and/or sinteres subsequent layers of powder
Implementation Method 3
The filter receives an incoming mixture of air and oil on one of its faces and allows the air to pass through, trapping the oil particles in the pores in the metal foam
Implementation Method 4
Due to the effect of the rotation of the rotor the oil is made to pass radially through the pores, before being discharged and flowing out towards a tank
Data Source
Figure 1~2
Figure 3A~3B
Figure 3C~3D
AI summary
A filter (4), in particular for a rotary separator (1), is produced using an energy beam melting process, for example an electron beam, starting from powder made from the same material as a porous filtering portion (10) to be formed, for example from a titanium alloy; on the basis of a three-dimensional model comprising a cell structure defining the porous filtering portion (10), subsequent layers of powder (22) are applied and locally melted, so as to form successive sections (170) of the porous filtering portion (10); at the end of the forming process, the residual powder is evacuated from the pores.