Patent Grant
11059053
The present invention relates to a centrifugal separator structure for cleaning of crankcase gases emanating from an internal combustion engine, as well as to an assembly comprising a centrifugal separator structure for cleaning of crankcase gases emanating from an internal combustion engine.
Crankcase gases from an internal combustion engine are ventilated from a crankcase of a relevant combustion engine. Crankcase gases may be disposed of in an environmentally friendly manner instead of being ventilated in untreated form to the atmosphere. For certain types of combustion engines, legislation requires crankcase gases to be disposed of in an environmentally friendly manner.
Crankcase gases may comprise inter alia blow-by gases, oil, other liquid hydrocarbons, soot, and other solid combustion residues. In order to dispose of crankcase gases suitably, the gas is separated from oil, soot, and other residues. The separated gas may be led to an air intake of the combustion engine or vented to the atmosphere, and the oil may be led back to an oil sump of the combustion engine optionally, via an oil filter for removing soot and other solid residues from the oil.
A centrifugal separator may be used for disposing of crankcase gases. Separation discs in the form of truncated conical discs, of the centrifugal separator, are arranged in a disc stack with small interspaces between the separation discs. The crankcase gases are led into the rotating disc stack and heavy constituents of the crankcase gases, such as oil and soot, are forced against inner surfaces of the separation discs and form droplets as they travel along the separation discs towards an outer periphery of the disc stack. The droplets are thrown onto an inner wall of a housing of the centrifugal separator and are led out of the centrifugal separator via an oil outlet. The cleaned crankcase gases are led out of the centrifugal separator via a gas outlet.
SE 519180 discloses a centrifugal filter for removing oil and particles from crankcase gases in an internal combustion engine with closed crankcase ventilation. The centrifugal filter comprises a number of truncated conical discs arranged on a rotor axle of the centrifugal filter. The rotor axle is supported in a bearing in a housing of the centrifugal filter. A pulley is arranged on the rotor axle. The crankshaft of the internal combustion engine drives a number of auxiliary devices via a belt circuit, including the centrifugal filter.
WO 2004/001201 discloses a gas cleaning separator. For cleaning of crankcase gas produced by an internal combustion engine use is made of a centrifugal rotor, which is journaled in a housing by two axially separated bearings. A rotor body of the centrifugal rotor comprises a large number of conical separation discs. The centrifugal rotor is rotated by an electrical motor integrally arranged with the centrifugal rotor. The electrical motor has a stator, which is kept non-rotating and is charged with electric current for rotation of the centrifugal rotor.
An engine compartment of a modern vehicle is packed with a multitude of different components. Thus, space is limited and there is a general desire in the vehicle industry to provide more space in an engine compartment.
It is an object of the present invention to reduce the volume occupied by a centrifugal separator for cleaning of crankcase gases emanating from an internal combustion engine.
According to an aspect of the invention, the object is achieved by a centrifugal separator structure configured for cleaning of crankcase gases from an internal combustion engine. The centrifugal separator structure comprises a stationary housing and a separator rotor configured for rotation about a centre axis arranged inside the stationary housing. The stationary housing comprises an inlet for crankcase gases, a gas outlet, and a liquid outlet. The separator rotor comprises a stack of separation discs, each separation disc of the stack of separation discs having a truncated conical shape. The separator rotor comprises an axle member. The axle member is configured for connection to a shaft of a driving device for the centrifugal separator structure. The stack of separation discs is supported on the axle member.
Since the separator rotor comprises an axle member, the stack of separation discs being supported on the axle member, and which axle member is configured for connection to a shaft of a driving device for the centrifugal separator structure, the centrifugal separator structure is provided for connection to any separate driving device having an available rotatable shaft. The separator rotor thus, is driven together with the driving device.
Accordingly, the centrifugal separator structure together with the driving device forms a unit which is operable as a centrifugal separator for cleaning of crankcase gases. Thus, the space that would be required for a separate drive means for a centrifugal separator having its own driving means is saved. As a result, the above mentioned object is achieved.
The centrifugal separator structure is a separate unit configured for attachment to the driving device. The stationary housing is stationary in relation to the separator rotor during use of the centrifugal separator structure for cleaning of crankcase gases. Herein the term cleaning of crankcase gases relates to separation of liquid and solid residues from gaseous blow-by gases of a crankcase of an internal combustion engine.
According to embodiments, the axle member may be un-journaled inside the stationary housing when the centrifugal separator structure is separate from the driving device. Accordingly, the axle member may not be journaled in the stationary housing of the centrifugal separator. Instead, the axle member and the separator rotor may be journaled via bearings of the driving device. Put differently, the axle member and the separator rotor cannot rotate freely inside the stationary housing unless the centrifugal separator structure is connected to the driving device. The centrifugal separator may thus be free of bearings that journal the axle member and separator rotor.
However, it is to be understood that the axle member and the rotor also may be journaled, e.g. by means of bearings, within the centrifugal separator.
According to embodiments, the axle member may comprise a sleeve configured for receiving the shaft of the driving device. In this manner the axle member may easily be centred on the shaft of the driving device. The axle member may further configured to form a spline connection with a shaft of a driving device. Thus, the axle member may comprise a solid shaft with a spline connection. The axle member may further be configured to form a threaded connection with a shaft of a driving device. Thus, the axle member may comprise a solid shaft with a threaded connection.
According to a further aspect of the invention, the above mentioned object is achieved by an assembly comprising a centrifugal separator structure according to any one of aspects and/or embodiments disclosed herein and a driving device connected to the centrifugal separator structure. The axle member of the centrifugal separator structure is connected to a shaft of the driving device. The axle member is supported by the shaft of the driving device such that the separator rotor is rotatable within the stationary housing about the centre axis by the driving device.
Since the axle member of the centrifugal separator structure is connected to the shaft of the driving device, and since the axle member is supported by the shaft of the driving device, the separator rotor is driven together with the driving device. Thus, the space that would be required by a separate drive means for the centrifugal separator is saved. As a result, the above mentioned object is achieved.
The driving device may be configured for rotating the separator rotor of the centrifugal separator structure and at least one unit other than the centrifugal separator. The shaft of driving device may thus be configured for transmitting torque to the separator rotor of the centrifugal separator structure and to at least one unit other than the centrifugal rotor. Thus, the driving device may be used for rotating both the centrifugal separator and another unit. In other words, a shaft that is arranged to be rotated by the driving device in another unit, i.e. in a unit different from the centrifugal separator, is also connected to the axle member so that the same shaft is used to rotate the centrifuge rotor and another unit. The driving device may for example be an electric current generator, a water pump, a wheel of a belt circuit of a combustion engine or an engine.
In the assembly the two separate units formed by each of the centrifugal separator structure and the driving device are connected to form one single unit.
According to embodiments, the driving device may be an electric current generator of an internal combustion engine, the electric current generator comprising a stator and a generator rotor configured for rotation inside the stator. The generator rotor may comprise the shaft of the driving device forming a rotor axle of the generator rotor. The rotor axle may extend along the centre axis.
However, the shaft may also be a shaft of other driving devices, such as a shaft of a water pump, an axle to the wheel of a belt circuit of a combustion engine or a cam shaft. The shaft may be driven by e.g. a belt drive or a direct drive using an electric motor.
As a further aspect of the invention, there is provided a method for cleaning a gas containing contaminants comprising the steps of
The step of providing a centrifugal separator also comprises rotating the separator rotor of the centrifugal separator.
In embodiments, gas containing contaminants is crankcase gas of a combustion engine and said contaminants comprise oil.
Further features of, and advantages with, the present invention will become apparent when studying the appended claims and the following detailed description.
Various aspects of the invention, including its particular features and advantages, will be readily understood from the example embodiments discussed in the following detailed description and the accompanying drawings, in which:
Aspects of the present invention will now be described more fully. Like numbers refer to like elements throughout. Well-known functions or constructions will not necessarily be described in detail for brevity and/or clarity.
The separator rotor 10 comprises an axle member 9. The axle member 9 is configured for connection to a shaft of a driving device for the centrifugal separator structure 4. The axle member 9 comprises a sleeve 13 configured for receiving the shaft of the driving device. The stack 18 of separation discs 20 is supported on the axle member 9. The centre axis 22 extends centrally through the separation discs 20 and in this embodiment through the axle member 9.
The centrifugal separator structure 4 is a separate unit configured for connection to a relevant driving device. Thus, when the centrifugal separator structure 4 is connected to the driving device, and the axle member 9 is connected to a shaft of the driving device, the centre axis 22 is aligned with the shaft of the driving device, see
The axle member 9 is un-journaled inside the stationary housing 8 when the centrifugal separator structure 4 is separate from the driving device. The axle member 9 is not journaled in the stationary housing 8 of the centrifugal separator structure 4. When the centrifugal separator structure 4 is not connected to a driving device, the separator rotor 10 may rest against one or more inner surfaces of the stationary housing 8. The axle member may thus be unsupported inside the stationary housing except for any inner surface against which the axle member and rotor may rest. It is only when the axle member 9 is connected to the shaft of the driving device that the axle member 9 may be journaled. Namely, journaled via bearings of the driving device. Accordingly, the separator rotor 10 cannot rotate freely inside the stationary housing 8 unless the centrifugal separator structure 4 is connected to the driving device, see further below with reference to
The inlet 12 for crankcase gases is configured to be in a permanent open connection with an internal space of a crankcase of the internal combustion engine. Thus, the centrifugal separator structure 4 is continuously available for cleaning of crankcase gases.
The inlet 12 for crankcase gases may be configured to direct crankcase gases towards a central portion of the stack 18 of separation discs 20. In this manner the flow of the crankcase gases through the centrifugal separator structure 4 may be controlled.
The liquid outlet 16 may be arranged at a peripheral outer portion of the stationary housing 8. A check valve 54 may be associated with the liquid outlet 16. In this manner inflow via the liquid outlet 16 may be prevented while separated liquid, such as oil containing residues, may flow out thorough the liquid outlet 16.
In this embodiment, the centrifugal separator structure 4 comprises a securing member 64 configured for securing the axle member 9 to the shaft 15 of the driving device 5. Thus, a distal end portion of the axle member 9 may be secured to the shaft 15 on a side of the stack 18 of separation discs 20 opposite the driving device 5. In these embodiments the securing member 64 comprises a bolt 65 secured in a threaded hole in the shaft 15. The securing member 64 may comprise an engagement member 67, such as a rubber bushing which expands when the bolt 65 is tightened. Alternatively, or additionally, the securing member may comprise splines, or a key for rotationally interlocking the axle member 9 with the shaft 15. Other kinds of suitable securing members are also foreseen.
The stationary housing 8 comprises an access opening 66 for fitting and/or accessing the securing member 64 inside the stationary housing 8. In this manner access for fastening or removing the securing member 64 may be provided. A cover 63 may be provided for closing the access opening 66.
The driving device 5 comprises a casing 72 in which the shaft 15 of the driving device 5 is journaled. In these embodiments the shaft 15 is journaled in two ball bearings 73 arranged in the casing 72. However, the shaft 15 may also be journaled to other parts than the casing of the driving device.
The stationary housing 8 comprises at least one connection member 68 for connecting the stationary housing 8 to the driving device 5. Thus, also the stationary housing 8 may be secured to the driving device 5. In these embodiments, the connection member 68 comprises a screw 70, by means of which the stationary housing 8 is fixed to the casing 72 of the driving device 5. Other kinds of suitable connecting members are also foreseen.
The driving device 5 comprises a drive wheel 30 connected to the shaft 15 of the driving device 5 at a first end portion 32 of the driving device 5. The drive wheel 30 is configured to be driven by an internal combustion engine. In this manner the centrifugal separator structure 4 may be driven by the internal combustion engine via the drive wheel 30 and the shaft 15.
The centrifugal separator structure 4 is arranged at a second end portion 34 of the driving device, opposite to the first end portion 32.
The stationary housing 8 comprises a proximal end portion 36 and a distal end portion 38. The proximal end portion 36 faces the second end portion 34 of the driving device 5. The axle member extends from the proximal end portion 36 of the stationary housing 8 adjacent to the driving device 5 to a distal end portion 38 of the stationary housing. The distal end portion of the axle member is configured for connection to the shaft 15 of the driving device.
The shaft 15 of the driving device 5 extends through the second end portion 34 and through the proximal end portion 36. A radial sealing 40 is provided around the axle member 9 for sealing off an inside of the stationary housing 8 towards the driving device 5. In this manner the driving device 5 may not be contaminated by the crankcase gases in the stationary housing 8 of the centrifugal separator structure.
In these embodiments the driving device 5 is an electric current generator 6 of an internal combustion engine. The electric current generator 6 comprises a stator 24 and a generator rotor 26 configured for rotation inside the stator 24. The generator rotor 26 comprises the shaft 15 of the driving device 5 forming a rotor axle. The rotor axle, i.e. the shaft 15 extends along the centre axis 22. Since the electric current generator 6 is always rotated when the internal combustion engine is running, the centrifugal separator 4 will also be running and thus, be available for the cleaning of the crankcase gases.
The electric current generator 6 comprises an electrical connector 46 arranged at the second end portion 34. In this manner the electric current generator may be connected to e.g. a battery of a relevant vehicle. Moreover, due to the electrical connector being arranged at the second end portion, the assembly does have limited radial extension.
The assembly 2 comprises a distance element 50 arranged between the stationary housing 8 and the second end portion 34. The distance element 50 at least partially encloses the electrical connector 46. Thus, the distance element 50 provides a space between the stationary housing 8 and the second end portion 34, in which space the electrical connector 46 is protected. In these embodiments the distance element 50 is connected to the stationary housing 8.
The electric current generator 6 is configured for use as an electric current generator connected to an internal combustion engine. The electric current generator 6 comprises a stator 24 and a generator rotor 26 configured for rotation inside the stator 24. The generator rotor 26 comprises a rotor axle 28. The rotor axle 28 extends along the centre axis 22. The rotor axle 28 is connected to the separator rotor 10. Again, the separator rotor 10 comprises an axle member 9 and a shaft 15 that forms the rotor axle 28.
The electric current generator 6 comprise a drive wheel 30 connected to the rotor axle 28. The drive wheel 30 is configured to be driven by the internal combustion engine. In these embodiments the drive wheel 30 comprises a pulley for a belt drive. In alternative embodiments, the drive wheel may for instance comprise a cog wheel.
The drive wheel 30 is arranged at a first end portion 32 of the electric current generator 6. The centrifugal separator structure 4 is arranged at a second end portion 34 of the electric current generator 6. The second end portion 34 is positioned opposite to the first end portion 32. The first and second end portions 32, 34 form axial end portions of the electric current generator 6, i.e. they form end portions along the centre axis 22.
The stationary housing 8 of the centrifugal separator structure 4 comprises a proximal end portion 36 and a distal end portion 38. The proximal end portion 36 faces the second end portion 34 of the electric current generator 6. The rotor axle 28 extends through the second end portion 34 of the electric current generator 6. The rotor axle 28 further extends through the proximal end portion 36 of the stationary housing 8. A radial sealing 40 is provided around the axle member 9 for sealing off an inside of the stationary housing 8 towards the electric current generator 6. The sealing 40 may comprise e.g. a simmering seal. Thus, crankcase gases, oil and soot will be prevented from leaking along the axle member 9 from the chamber 11 in the housing 8 of the centrifugal separator structure 4 into the electric current generator 6.
The inlet 12 for crankcase gases is configured to be in a permanent open connection with an internal space of a crankcase of the internal combustion engine. Thus, the centrifugal separator structure 4 is continuously available for cleaning of crankcase gases. Since the electric current generator 6 is always rotated when the internal combustion engine is running, the centrifugal separator structure 4 will also be running and thus, be available for the cleaning of the crankcase gases.
In these embodiments, the inlet 12 for crankcase gases is arranged at the proximal end portion 36. The inlet may alternatively be arranged at other portions of the centrifugal separator structure 4. Further, the inlet 12 is configured to direct crankcase gases towards a central portion 42 of the stack 18 of separation discs 20. Thus, an open connection is formed by the inlet 12 into the stack 18 of separation discs 20.
During operation of the assembly 2, the crankcase gases from the inlet 12 are distributed through the stack 18 via openings in the central portions of the separation discs 20. As the separator rotor 10 rotates, the crankcase gases are transported radially outwardly in the interspaces between the separation discs 20. Heavy constituents of the crankcase gases, such as oil and soot, are forced against inner surfaces of the separation discs 20 and form droplets as they travel along the separation discs 20 towards an outer periphery of the separator rotor 10. The droplets are thrown onto an inner wall 44 of the chamber 11 of the stationary housing 8 and are lead out of the centrifugal separator structure 4 via the liquid outlet 16. The cleaned crankcase gases are lead out of the centrifugal separator structure 4 via the gas outlet 14.
The gas outlet 14 is arranged at a central portion of the stationary housing 8, but may alternatively be arranged at the distal end portion 38, or at the proximal end portion 36, as in the embodiments of
The electric current generator 6 comprises an electrical connector 46 arranged at the second end portion 34. The electrical connector 46 may form part of a connection to e.g. a battery of a relevant vehicle. Further electrical components may form part of the connection to the battery, such as e.g. one or more diodes. Also arranged at the second end portion 34 may be further electrical elements and/or modules, such as e.g. a voltage regulator 48.
The assembly 2 comprises a distance element 50 arranged between the stationary housing 8 and the second end portion 34 of the electrical generator 6. The distance element 50 at least partially encloses the electrical connector 46. The distance element 50 may form a wall portion. The distance element 50 may be provided with openings, e.g. in the form of slits, for providing ventilation of the voltage regulator 48.
A check valve 54 is associated with the liquid outlet 16. That is, oil and soot may flow out of the stationary housing 8 via the check valve 54 and the liquid outlet 16, but inflow via the liquid outlet 16 is prevented by the check valve 54. For example, if the liquid outlet 16 is connected to the crankcase of a combustion engine, the inflow of crankcase gases into the centrifugal separator via the liquid outlet 16 is prevented by the check valve 54. When the pressure inside the stationary housing 8 of the centrifugal separator structure 4 is higher than the pressure in the crankcase of the combustion engine, the check valve 54 is open. If the pressure in the crankcase is higher than in the stationary housing 8, the check valve 54 is closed.
This invention should not be construed as limited to the embodiments set forth herein. A person skilled in the art will realize that different features of the embodiments disclosed herein may be combined to create embodiments other than those described herein, without departing from the scope of the present invention, as defined by the appended claims. Although the invention has been described with reference to example embodiments, many different alterations, modifications and the like will become apparent for those skilled in the art. Therefore, it is to be understood that the foregoing is illustrative of various example embodiments and that the invention is defined only by the appended claims.
As used herein, the term “comprising” or “comprises” is open-ended, and includes one or more stated features, elements, steps, components or functions but does not preclude the presence or addition of one or more other features, elements, steps, components, functions or groups thereof.
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