Rotating Air-Oil Separator with Segmented Flow Paths
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Solution Overview
Problem
Existing air-oil separators for aircraft engines are not efficient in separating air from oil, leading to reduced oil recovery and increased oil consumption, which affects engine autonomy and environmental sustainability.
Innovation Solution
The design incorporates a gearbox de-oiler with a rotating housing containing a porous separator matrix and a separation plate that divides the chamber into primary and secondary flow path segments, utilizing centrifugal force to separate oil from air and collect oil through oil collector tubes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional air-oil separator is used, then the structure is simple, but the oil separation efficiency is low
Solution Approach 1:
The separator chamber is divided into multiple flow path segments (primary and secondary flow paths) using separation plates, creating a multi-stage separation process that increases oil separation efficiency while maintaining manageable structural complexity
Solution Approach 2:
The separator utilizes the radial dimension by extending flow paths from the axial direction to the radial direction, increasing the effective flow length and separation efficiency without proportionally increasing the axial height of the separator
2Productivity
If the flow path length is increased to improve separation efficiency, then the oil separation efficiency improves, but the separator volume increases
Solution Approach 1:
The flow paths extend radially outward from the central axis to the outer circumferential wall, utilizing the radial dimension to achieve longer flow paths without increasing axial height, thereby improving separation efficiency while controlling overall separator volume
Solution Approach 2:
Multiple flow path segments are nested within the annular chamber, with primary and secondary flow paths arranged concentrically around the central axis, maximizing the use of available space to achieve long flow paths in a compact volume
3Productivity
If a porous separator matrix is used, then the separation efficiency improves, but the oil recovery is reduced
Solution Approach 1:
Oil collector tubes are positioned to extract oil from the flow paths before it can be absorbed by the porous separator matrix, ensuring that separated oil is recovered and returned to the lubrication system rather than lost to the matrix
Solution Approach 2:
The separation plates and oil collector tubes act as intermediaries between the porous separator matrix and the oil recovery system, directing oil flow to collection points while allowing the porous matrix to perform its separation function
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 configuration enhances the effective flow length of the separator, improving oil separation efficiency, reducing oil consumption, and increasing engine autonomy while minimizing environmental impact.
Implementation Method 1
a porous separator matrix dividing the annular chamber into a radially outer flow path segment and a radially inner flow path segment
Implementation Method 2
a porous separator matrix disposed in both the radially outer flow path segment and the radially inner flow path segment
Implementation Method 3
utilizing centrifugal force to separate oil from air and collect oil through oil collector tubes
Implementation Method 4
a separation plate separating the porous separator matrix into a primary flow path segment and a secondary flow path segment, the primary flow path segment extending axially from and fluidly connecting the air-oil mixture inlet to a radial passage
Data Source
AI summary
A gearbox de-oiler comprises a housing mounted to a shaft for rotation therewith. The housing defines a chamber containing a porous separator matrix. The chamber has an air-oil mixture inlet, an oil outlet and an air outlet. A separation plate separates the porous separator matrix into a primary flow path segment and a secondary flow path segment. The primary flow path segment extends axially from and fluidly connects the air-oil mixture inlet to a radial passage. The secondary flow path segment extends axially from and fluidly connects the radial passage to the air outlet. The secondary flow path segment axially overlaps the primary flow path segment and is disposed radially inwardly with respect thereto. Oil collector tubes projects radially outwardly from the separation plate across at least a portion of the primary flow path segment for fluidly connecting the secondary flow path segment to the oil outlet.