Separator Nozzle Cover Device for Crankcase Gas Flow Control
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Solution Overview
Problem
Current oil separators in crankcase venting systems face challenges in effectively reducing gas flow through nozzles, leading to inefficiencies in oil separation and increased risk of oil contamination, which affects emission regulations and engine performance.
Innovation Solution
A separator design featuring a nozzle carrier element with a permanent cover device that reduces gas flow through nozzles by at least 50%, allowing for adjustable configurations during assembly or servicing to achieve varying throughput levels without the need for a valve or filter element, enabling production of separators for different performance classes with identical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If nozzles are left free without cover device, then gas flow throughput is high, but oil separation efficiency deteriorates
Solution Approach 1:
The separator is divided into multiple nozzles, each independently controllable by individual cover devices. This segmentation allows selective coverage of specific nozzles to optimize the balance between gas flow throughput and oil separation efficiency for different operating conditions.
Solution Approach 2:
The cover devices are designed to be adjustable and removable, allowing the system to dynamically adapt between different operating modes. During assembly or servicing, operators can selectively cover nozzles based on required performance levels, transforming a static system into a dynamically adaptable one.
2Reliability
If cover device is installed on nozzles, then oil separation efficiency improves, but gas flow throughput decreases
Solution Approach 1:
The cover devices provide localized modification of nozzle characteristics. By covering only specific nozzles rather than all nozzles uniformly, the system can create local variations in flow patterns that enhance oil separation in critical areas while maintaining adequate throughput through uncovered nozzles.
3Ease of operation
If valve or filter element is used to control gas flow, then gas flow can be regulated, but device complexity increases
Solution Approach 1:
The invention extracts the flow control function from complex valve mechanisms and filter elements, replacing them with simple cover devices that can be easily installed or removed. This extraction simplifies the overall device structure while retaining the essential capability to regulate gas flow through nozzles.
Solution Approach 2:
The cover devices are designed as simple, inexpensive components that can be easily replaced or adjusted. Rather than investing in complex, expensive valve or filter systems, the invention uses simple cover elements that achieve flow control through straightforward geometric modification, reducing both device complexity and maintenance costs.
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 reduces gas flow through nozzles by up to 95%, allowing for flexible assembly to accommodate different performance classes, minimizing oil consumption, and enhancing compliance with emission regulations by optimizing oil separation and reducing the need for filter element exchanges.
Implementation Method 1
A permanent cover device for one or more nozzles of the nozzle arrangement is provided that reduces by at least 50% a through-flow of the gas flow through the one or more nozzles
Implementation Method 2
a separator for separation of liquid from a gas flow, in particular for separation of oil from a blow-by gas in a crankcase venting system, comprising at least one nozzle carrier element with at least one nozzle arrangement with at least one nozzle, and comprising an impact element arranged downstream at least partially opposite the nozzle arrangement
Data Source
AI summary
A separator for separating liquid from a gas flow is provided with a nozzle carrier element provided with a nozzle arrangement having one or more nozzles. An impact element is arranged downstream in flow direction of the gas flow at least partially opposite the nozzle arrangement. A permanent cover device is provided that covers at least one of the one or more nozzles of the nozzle arrangement. The permanent cover device reduces by at least 50% a through-flow of the gas flow through the at least one of the one or more nozzles of the nozzle arrangement compared to the one or more nozzles of the nozzle arrangement that are free from the permanent cover device. An assembly kit for producing such a separator is provided with a nozzle carrier element with nozzle arrangement and one or more nozzles, an impact element, a cover device, and a liquid reservoir.