Separator Actuator Diaphragm Support to Prevent Inversion
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Solution Overview
Problem
Conventional engine blow-by gas separators face challenges in maintaining diaphragm stability during unexpected pressure increases and high flow events, which can lead to diaphragm inversion and loss of pressure control, potentially damaging engine seals.
Innovation Solution
An actuator system with a flexible diaphragm and a support assembly that includes a diaphragm anti-inversion feature, where the upper support member has a radially extending portion and a diaphragm anti-inversion feature extending axially to prevent inversion by acting as a physical barrier and fixing the diaphragm's pivot point, ensuring the diaphragm remains in its natural position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the separator uses a flexible diaphragm to control pressure differential, then the separator can maintain pressure control and prevent oil leakage, but the diaphragm may invert during unexpected pressure increases and high flow events, leading to loss of pressure control
Solution Approach 1:
The actuator support assembly is designed with features that prevent diaphragm inversion before it can occur during unexpected pressure increases. The support assembly structurally constrains the diaphragm to maintain its intended configuration, counteracting the inversion tendency proactively rather than reactively.
Solution Approach 2:
The actuator support assembly serves as a protective structure that cushions and supports the flexible diaphragm against inversion forces. This pre-positioned support structure absorbs and distributes the stresses during high flow events, preventing the diaphragm from inverting and maintaining pressure control reliability.
2Reliability
If the separator maintains high separation efficiency for oil aerosols, then emissions compliance is achieved, but the pressure differential across the separator must be kept below a strict limit, reducing the actuator's pressure control range
Solution Approach 1:
The actuator with a flexible diaphragm and movable support assembly provides dynamic pressure control, allowing the separator to adapt to varying engine operating conditions. The diaphragm can flex and the support assembly can move to maintain the required pressure differential within the 5-50 mbar range while handling different flow rates and separation demands.
Solution Approach 2:
The actuator system enables precise control of the pressure differential parameter across the separator by adjusting the aperture opening area. This allows the separator to maintain high separation efficiency while operating within the strict pressure differential limits, as the actuator can modulate the opening to optimize both separation performance and pressure control.
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 effectively prevents diaphragm inversion, maintaining stable pressure control and preventing damage to engine seals by ensuring the diaphragm remains in its natural position during pressure fluctuations and high flow events, enhancing the separator's performance and reliability.
Implementation Method 1
an actuator which is arranged to move along an actuator axis to adjust an open cross-sectional area of at least one aperture of the separator through which the fluid stream flows
Implementation Method 2
an impaction surface located downstream of the chamber, which is arranged to deflect the fluid stream after the fluid stream leaves the chamber such that contaminants are separated from the fluid stream
Data Source
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AI summary
There is disclosed an actuator (55) for a separator (5) for separating contaminants from a fluid stream which includes entrained contaminants. The actuator is arranged to move along an actuator axis (56) to adjust an open cross-sectional area of at least one aperture (29) of the separator through which the fluid stream flows, and comprises a flexible diaphragm (31) for occluding the at least one aperture, and a support assembly (33) for the flexible diaphragm. The support assembly is movable along the actuator axis carrying the flexible diaphragm and has a lower support member (58) and an upper support member (60) mounted on the lower support member so that a portion of the flexible diaphragm is located between the upper and lower support members. The lower support member comprises a radially extending support portion (62) and an axially extending support portion (64) coupled to the radially extending support portion. The upper support member comprises a radially extending support portion (66) and a diaphragm anti-inversion feature (68) coupled to the radially extending support portion. The diaphragm anti-inversion feature extends in an axial direction so that it axially overlaps at least part of the axially extending support portion of the lower support member.