The present disclosure relates to devices for separating and capturing debris particles from a fluid circulating through a fluid system, including a separator assembly having multiple separator stages to discretize debris particles of differing sizes and weights.
Separator assemblies can be used in a wide-variety of fluid systems, such as fluid lubrication systems, to separate and capture debris particles from fluid circulating through the system. One type of separator assembly, for example, is a cyclonic separator. A cyclonic separator assembly may generally include a circular cylindrical housing having a first or top end and a second or bottom end. The first end may be closed by an end wall and the second end may define an opening. An inlet for fluid may be located near the first end of the housing. The inlet can define a flow path that opens in a generally tangential direction within the housing. The separator assembly may also include a debris separation wall disposed within the housing. The debris separation wall may circumferentially extend around an inner surface of the housing and can define an annular collection region.
When fluid enters the housing via the inlet, the fluid can be directed in a cyclonic flow pattern as a result of gravity and the inlet being tangential to the circular cylindrical housing. As the fluid flows in a cyclonic motion down through the housing, debris particles may migrate radially outwardly within the fluid toward the inner surface of the housing due to centrifugal forces. As the fluid flows downwardly over the separation wall, the debris particles may be captured in the collection region of the separation wall. The fluid may then exit the housing through the opening in the second end.
A sensor may be provided near the collection region to detect accumulation of debris particles. The sensor may also provide a signal when the size of captured particles reaches a predetermined threshold. However, the accumulation of relatively smaller debris particles can build up and, over time, may exceed a saturation mass of the sensor. As a result, this may “blind” the sensor from detecting debris particles that are of particular interest.
Thus, although known separator assemblies may function in an acceptable manner, it would be desirable to provide an improved separator assembly having multiple separator stages to discretize particles of differing sizes and weights and to provide improved separation of debris particles.
A separator assembly is provided for, among other things, separating debris particles from a fluid in a fluid system. In an embodiment, the separator assembly may include a housing forming an internal chamber. An inlet port may be in fluid communication with the internal chamber, and the inlet port can be oriented in a tangential relationship relative to the internal chamber of the housing. A first debris separation ring may be disposed in the housing and can extend around an inner surface of the internal chamber. A second debris separation ring can be disposed in the housing and can extend around the inner surface of the internal chamber, wherein the second debris separation ring may be spaced from the first debris separation ring.
Various aspects of the present disclosure will become apparent to those skilled in the art from the following detailed description of the various embodiments, when read in light of the accompanying drawings.
Embodiments of the present disclosure will now be described, by way of example, with reference to the accompanying drawings.
Reference will now be made in detail to embodiments of the present disclosure, examples of which are described herein and illustrated in the accompanying drawings. While the invention will be described in conjunction with embodiments, it will be understood that they are not intended to limit the invention to these embodiments. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the invention as defined by the appended claims.
Referring now to
As generally shown, the separator assembly 10 may include a housing 12. The housing 12 can be a substantially circular cylindrical housing generally having a first end 14 and a second end 16. In a non-limiting embodiment, the first end 14 may be a top of the separator assembly 10 and the second end 16 may be a bottom of the separator assembly 10, respectively. The first end 14 of the housing 12 may comprise an end wall 14A and the second end 16 may define an outlet opening 16A. The housing 12 may form an internal chamber 18 (see
In a non-limiting embodiment, the separator assembly 10 may include a support flange 20. For example, the support flange 20 may be configured to support the separator assembly 10 on a reservoir or other suitable structure of the lubrication system. As generally shown, the support flange 20 may be provided near the second end 16 of the housing 12 and can radially extend outwardly from an outer surface of the housing 12, although such is not required. In turn, the support flange 20 may be secured to the reservoir or other support structure using threaded fasteners or another suitable connection. It should be appreciated, however, that the separator assembly 10 may include other suitable support members or can be secured to the reservoir in other ways without departing from the scope of the present disclosure.
The separator assembly 10 may also include an inlet port 22 that can be configured to supply fluid to the housing 12. For example, the inlet port 22 can define a fluid path that extends through a side wall of the housing 12 for fluid communication with the internal chamber 18 (see
As generally shown, the inlet port 22 may be oriented in a tangential relationship relative to the housing 12. In other words, the inlet port 22 can be generally perpendicular to a longitudinal axis of the housing 12 and radially spaced from the longitudinal axis. As such, the fluid path defined by the inlet port 22 may enter the internal chamber 18 (see
Referring now to
In another embodiment, the separator assembly 10, for example, as shown in
As generally shown, the separator assembly 10 may also include one or more debris separation rings 30 disposed within the internal chamber 18 of the housing 12. For example, in a non-limiting embodiment, such as generally illustrated in
As generally disclosed below, the debris separation rings 30 may be configured to help separate and capture debris particles from fluid circulating through the housing 12. In an embodiment, the first and second debris separation rings 30A and 30B may be similar to one another in structure. Therefore, only the first debris separation ring 30A is generally disclosed in further detail below. It should be appreciated, however, that the first and second debris separation rings 30A and 30B need not be similar to one another, but may have different structural features or configurations.
As generally shown, the first debris separation ring 30A may be a generally annular ring that circumferentially extends around an inner surface of the housing 12. For example and without limitation, the first debris separation ring 30 may include a radially extending wall 32A and an axially extending wall 34A. The radially extending wall 32A may radially extend inwardly from the inner surface of the housing 12. The axially extending wall 34A may axially extend from an inner circumferential edge of the radially extending wall 32A so as to be generally parallel with and radially spaced from the inner surface of the housing 12. As such, an annular pocket or collection region 36A can be formed between the inner surface of the housing 12, the radially extending wall 32A, and the axially extending wall 34A. As generally disclosed below, a size and/or cross-sectional shape of the annular collection region 36A may be optimized or otherwise configured to achieve maximum separation and capture of debris particles having a particular size and/or a predetermined range of sizes. The debris separation rings 30 may have any suitable shapes or configurations without departing from the scope of the present disclosure.
It should also be appreciated that the debris separation rings 30 can be secured to or otherwise supported within the housing 12 using a suitable connection including, but not limited to, a press-fit connection, an adhesive, a welded connection, or another suitable connection. In other embodiments, for example, the debris separation rings 30 may be molded with the housing 12 using a suitable molding process.
In another embodiment, the separator assembly 10 may include a generally conically shaped debris separation ring 30, such as generally illustrated in
The debris separation ring 30 may include a second wall 34′ that extends conically from an inner circumferential edge of the first wall 32′ at a predefined obtuse angle α relative to the first wall 32′ such that the second wall 34′ may define a conically shaped portion 35 of the debris separation ring 30.
The portion 35 includes a first diameter D1 disposed near the first wall 32′ and a second diameter D2 disposed near an end of the second wall 34′. The end of the second wall 34′ may be opposed to the first wall 32′. In the illustrated embodiment, the second diameter D2 is smaller than the first diameter D1. As such, an annular pocket or collection region 38 can be formed between the inner surface of the housing 12, the first wall 32′, and the second wall 34′.
A size and/or cross-sectional shape of the annular collection region 38 may be optimized or otherwise configured to achieve improved (or even maximum) separation and capture of debris particles having a particular size and/or a predetermined range of sizes and to allow nuisance debris to be washed back into fluid exiting the separator assembly 10 through the opening 16A. Nuisance debris may be debris of a particular size or material that is not monitored by the sensor 50. For example, and without limitation, debris that is smaller than a particular size may be considered nuisance debris. As fluid, which may contain debris, including nuisance debris, is circulated through the housing 12, the nuisance debris may build up on a surface of the sensor 50. Overtime, enough nuisance debris build up may “blind” the sensor 50. In other words, functionality of the sensor 50 may be diminished as a result of nuisance debris build up. By allowing the nuisance debris to wash back into the fluid exiting the separator assembly 10, a reduced amount of nuisance debris is available to build up on the sensor 50, thereby, delaying, or preventing, sensor “blinding”.
The size of the collection region 38 is related to the value of the angle α. For example, the angle α may be greater than 90° (i.e., an obtuse angle) relative to the first wall 32′, such as generally illustrated in
Referring again to both debris separation rings 30, as generally shown in
The separator assembly 10 may also include a plurality of debris ports, such as a first debris port 40A and a second debris port 40B (collectively “the debris ports 40”). As generally disclosed below, the debris ports 40 may be configured to collect debris particles that are captured by the respective debris separation rings 30. In an example and without limitation, the debris ports 40 may extend through the side wall of the housing 12 and can be in communication with the collection regions 36 of the respective debris separation rings 30. In this example, the first debris port 40A may be provided radially adjacent to the collection region 36A of the first debris separation ring 30A, and the second debris port 40B may be provided radially adjacent to the collection region 36B of the second debris separation ring 30B. It should be appreciated that the number of debris ports 40 may correspond to the number of debris separation rings 30, although such is not necessarily required. Further, as generally disclosed below, the dimensions and shape of the debris ports 40 may be optimized to respectively collect debris particles having a predetermined size or a range of sizes, if desired.
The separator assembly 10 may also include a plurality of sensors, such as a first sensor 50A and a second sensor 50B (collectively “the sensors 50”). The sensors 50 may be configured to detect the presence of debris particles in the respective debris ports 40. The sensors 50 may also provide an electronic signal to a control unit, for example, when a size of the captured debris particles reaches a predetermined threshold and/or falls within a specified range. For example and without limitation, a portion of the first sensor 50A may be in communication with the first debris port 40A of the first debris separation ring 30A, and a portion of the second sensor 50B may be in communication with the second debris port 40B of the second debris separator ring 30B. It should be appreciated that the number of sensors 50 may correspond to the number of debris separation rings 30 and debris ports 40, although such is not necessarily required.
In an embodiment, the sensors 50 may be removably supported on or otherwise attached to the housing 12. As such, the sensors 50 can be removed in order to, among other things, gain access to the debris ports 40 for removal of debris particles. For example, as generally shown, the sensors 50 may be respectively inserted into support sleeves 52A and 52B (collectively “the support sleeves 52”) that can be formed in or otherwise provided adjacent to the side wall of the housing 12. In an embodiment, the supports sleeves 52 can be oriented in a generally perpendicular relationship relative to the longitudinal axis of the housing 12. However, the support sleeves 52 may also be oriented in any suitable relationship relative to the longitudinal axis. Further, the sensors 50 may be removably secured within the support sleeves 52 in any suitable manner including, but not limited to, a threaded connection, a press-fit connection, or a quick-disconnect style connection. A sealing member (e.g., an o-ring) may be optionally provided between each of the sensors 50 and the respective support sleeves 52 to form a sealed connection with the housing 12. In other embodiments, however, the sensors 50 may supported on or otherwise attached to the housing 12 in other suitable ways without departing from the scope of the present disclosure.
As briefly mentioned above, the sensors 50 may be configured to detect debris particles in the respective debris ports 40. For example and without limitation, the sensors 50 may be magnetic induction sensors that can be configured to detect the presence of metallic particles in the debris ports 40. It should be appreciated, however, that the sensors 50 may be other suitable sensors capable of detecting debris particles. As generally disclosed below, the respective sensors 50 may be individually optimized or otherwise calibrated to detect debris particles having different sizes and/or that fall within different specified ranges. In this example, and without limitation, the first sensor 50A can be optimized or calibrated to detect debris particles having a first or relatively larger size, while the second sensor 50B can be optimized or calibrated to detect debris particles having a second or relatively smaller size, or vice versa.
As generally shown in
In a similar manner, an inner diameter of the respective debris separation rings 30 may progressively increase in size from the first end 14 of the housing 12 to the second end 16, although such may not be required. For example and without limitation, the first debris separation ring 30A may have a first inner diameter DR1, and the second debris separation ring 30B may have a second inner diameter DR2 that is larger than the first inner diameter DR1. If more than two debris separation rings 30 are provided, it should be appreciated that the inner diameters of the additional debris separation rings 30 may continue to progressively increase in size. Further, as described above, it should be appreciated that the relative increase in the respective inner diameters of the debris separation rings 30 may be optimized or otherwise configured to achieve maximum discretization and capture of debris particles having varying sizes and weights. As generally shown, the debris separation rings 30 may be concentrically aligned with one another relative to the longitudinal axis of the housing 12, although such may not be required.
An operation of the separator assembly 10 in accordance with the present disclosure will now be generally described with reference to
As a result of centrifugal force, relatively larger and heavier debris particles may tend to migrate outwardly towards the inner surface of the housing 12 more quickly than relatively smaller and lighter debris particles. Thus, in the embodiment generally depictured in
As debris particles are captured by the one or more debris separation rings 30, they may be directed to the respective debris ports 40 where debris particles of a predetermined size and/or material can be detected by the sensors 50. As such, debris particles and other contaminates that are collected by the debris separation rings 30 can, when necessary, be removed from the separator assembly 10. As generally explained above, the debris particles can be removed from the separator assembly 10 by removing the sensors 50 from the housing 12.
To help reduce or prevent the sensors 50 from being “blinded” by nuisance debris, the respective debris ports 40 may also be optimized or otherwise configured to collect debris particles having a particular size and/or a predetermined range of sizes. It should also be appreciated that the respective sensors 50 may be individually optimized or calibrated to detect debris particles having a particular size and/or a predetermined range of sizes. Further, in the embodiment illustrated in
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and various modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to explain the principles of the invention and its practical application, to thereby enable others skilled in the art to utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims and their equivalents.
This application claims the benefit of U.S. Provisional Patent Application No. 61/987,627, filed May 2, 2014, which is hereby incorporated by reference as though fully set forth herein.
Filing Document | Filing Date | Country | Kind |
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PCT/US2015/028811 | 5/1/2015 | WO | 00 |
Number | Date | Country | |
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61987627 | May 2014 | US |