GAS CLEANING SEPARATOR AND METHOD FOR ASSEMBLING A GAS CLEANING SEPARATOR

专利摘要:
Gas cleaning separator, and method for assembling a gas cleaning separator The present invention relates to a separator and, more specifically but not exclusively, to a centrifugal separator for cleaning a gaseous fluid. a centrifugal separator (2 ') is provided as comprising a housing (4') defining an internal space and a rotor unit (78 ', 84', 86 ') for granting a rotary motion in a mixture of substances to be separated. the rotor unit (78 ', 84', 86 ') is located in said internal space and is rotatable about a geometrical axis (64') relative to the housing (4 '). the rotor unit comprises an inlet (600) for receiving said substance mixture, an outlet (604) from which said substances are ejected from the rotor unit during use and a flow path (602) for providing fluid communication between the inlet (600) and outlet (604), wherein outlet (604) is positioned more radially outwardly from said geometry axis (64 ') than inlet (600).
公开号:BR112012000526B1
申请号:R112012000526-0
申请日:2009-07-10
公开日:2019-10-08
发明作者:Olle Törnblom；Thomas Eliasson；Janke Burmeister；Mats-Örjan Pogén；Per Stjernswärd
申请人:Alfa Laval Corporate Ab；
IPC主号:

专利说明:

“GAS CLEANING SEPARATOR, AND, METHOD FOR ASSEMBLING A GAS CLEANING SEPARATOR”
The present invention relates to a separator and, more specifically but not exclusively, to a centrifugal separator for cleaning a gaseous fluid.
It is well known that a mixture of fluids having different densities can be separated from each other through the use of a centrifugal separator. A specific use of such a separator is in the separation of vented gas oil from an internal combustion engine crankcase.
With regard to this specific use of separators, it is well known that there is a tendency for high pressure gases in the combustion chambers of an internal combustion engine to leak beyond the associated piston rings and into the engine's crankcase. This continuous leakage of gas into the sump can result in an undesirable pressure increase inside the sump and, as a consequence, a need to vent gas from said sump. In large commercial vehicles, vented gas is usually reintroduced into the engine's intake line. However, the vented crankcase gas typically contains an amount of engine oil (such as droplets or a fine mist), which is collected from the oil reservoir kept inside the crankcase. More specifically, the gas flowing between an engine cylinder and the associated piston tends to collect lubricating oil located on the cylinder wall. Also, condensation of oil vapor by an engine cylinder block cooling system generates an oil mist inside the crankcase.
In order to allow vented gas to be introduced into the intake system without also introducing unwanted oil (particularly within a turbocharging system where the efficiency of the compressor may be adversely affected by the presence of coking oil), it is necessary to clean the gas vented (ie, remove the oil charged by the gas) before the gas is introduced into the intake system. This cleaning process can be performed by a centrifugal separator, which is mounted on or adjacent to the sump and which directs clean gas to the intake system and directs the separated oil back to the sump.
A centrifugal separator that has performed the task described above with significant commercial success is the applicant's ALFDEX ™ separator. This prior art separator is described below, with reference to the accompanying drawings, in detail in order to clearly illustrate the developments of the present invention, which are described subsequently.
There are a number of problems associated with the prior art ALFDEX ™ separator. These problems can be considered in three broad categories.
First, the fluid paths through the separator give rise to pressure losses that adversely affect the flow capacity of the separator and, consequently, the size of the motor with which the separator can be used. A first category of problem associated with the prior art ALFDEX ™ separator can therefore be considered to be related to pressure losses in the fluid flow paths.
Second, the arrangement of the prior art separator is such that, under certain conditions, the clean gas can become contaminated before leaving the separator. Thus, a second category of problem associated with the prior art separator can be considered to be related to an undesirable oil contamination of the clean gas.
Third, certain manufacturing techniques and construction details associated with the prior art separator can result in assembly difficulties and / or reliability problems. As such, a third category of problem associated with the prior art separator can be considered to be related to the manufacture and reliability of the separator.
Each of these categories will be discussed in more detail below.
A first aspect of the present invention provides a gas cleaning separator (2 ') to separate a flowable mixture of substances of different densities, such as a gas and liquid, the separator (2') comprising:
a housing (4 ') defining an internal space and at least one blade element (116') located in said space and rotating around a geometric axis (64 '), in order to grant movement in a mixture of substances to be separate;
characterized by the fact that a leading edge part (310) of the or each blade element (116 ') comprises a guide surface so that, in use, a mixture of substances flowing towards said edge part of Feed (310) is guided by the guide surface for alignment with the paddle element (116 ').
Other details of the invention are provided in a separator as narrated below:
A separator (2 ') as described above with reference to the first aspect of the invention, the separator (2') comprising a plurality of said blade elements (116 ') equi-spaced about said geometric axis (64').
A separator (2 ') as narrated above with respect to the first aspect of the invention, the separator (2') comprising twelve of said blade elements (116 ') located around said geometric axis (64').
A separator (2 ') as listed above with respect to the first aspect of the invention, wherein said guide surface comprises a curved part.
A separator (2 ') as listed above with respect to the first aspect of the invention, wherein said guide surface is provided by a guide vane (314) extending from said leading edge part (310).
A separator (2 ') as listed above with respect to the first aspect of the invention, wherein the guide vane (314) of a paddle element (116') is arranged at an angle (322) with said paddle element (116 '), so that, for a given rotational speed of said blade element (116') around said geometric axis (64 ') and for a given flow speed of said mixture, the guide vane (314) is substantially in line with the mixture flow.
A separator (2 ') as listed above with respect to the first aspect of the invention, wherein the separator (2') further comprises at least one separating disc (82 ') rotating about said geometric axis (64') and located in said space, in order to receive said substances of a shovel element (116 ').
A separator (2 ') as listed above with respect to the first aspect of the invention, wherein the separator (2') comprises a plurality of separation discs (82 ') arranged in a stack (84'), rotating about the same geometric axis (64 ') and located in said space in order to receive said substances of said blade element (116').
A separator (2 ') as listed above with respect to the first aspect of the invention, wherein said geometrical axis (64') of or of each separation disc (82 ') is coincident with said geometrical axis (64') of the element of paddle (116 ').
A second aspect of the present invention provides a gas cleaning separator (2 ') to separate a flowable mixture of substances of different densities, such as a gas and a liquid; the separator (2 ') comprising:
a housing (4 ') defining an internal space, a rotor unit (78', 84 ', 86') to provide a rotary movement over said mixture of substances, the rotor unit (78 ', 84', 86 ') being located in said internal space and rotating around a geometric axis (64 ') relative to the housing (4'), in which the rotor unit comprises an inlet (600) to receive said mixture of substances, an outlet (604) that said substances are ejected from the rotor unit during use, and a flow path (602) to provide fluid communication between the inlet (600) and the outlet (604), in which the outlet (604) is positioned more radially to outside said geometric axis (64 ') than the entrance (600); and a housing member (72 ') defining a region (606) for receiving fluid ejected from the rotor unit (781, 84', 86 ') and directing said fluid to a first outlet opening (10') of the housing (4 ', 70');
characterized in that an entrance (610) to said region (606) comprises at least one longitudinal part (612) of greater depth (613) than other longitudinal parts of said entrance (610).
Other details of the invention are provided in a separator as listed below:
A separator (2 ') as listed above with respect to the second aspect of the invention, wherein said housing member (72') is located adjacent an end member (86 ') of the rotor unit (78', 84 ', 86 '), said region (606) being defined between the extreme member (86') and the accommodation member (72 ').
A separator (2 ') as listed above with respect to the second aspect of the invention, wherein said entry (610) for said region (606) is defined by the outer member (86') and a perimeter edge (274) of the member of accommodation (72 ').
A separator (2 ') as related above with respect to the second aspect of the invention, wherein said perimeter edge (274) is circular, so that the longitudinal parts of said region entry (610) extend circumferentially along said edge (274).
A separator (2 ') as listed above with respect to the second aspect of the invention, in which the or each longitudinal part (612) of greater depth (613) is provided by a recess in said perimeter edge (274), which provides greater distance between said edge (274) and the end member (86 ') along one or each longitudinal part (612) than said edge (274) and the end member (86') along said other longitudinal parts.
A separator (2 ') as listed above with respect to the second aspect of the invention, wherein the circular perimeter edge (274) of the housing member (72') is concentric with said geometric axis (64 ').
A separator (2 ') as listed above with respect to the second aspect of the invention, wherein the or each longitudinal part (612) of greater depth (613) has a partially circular shape extending through an arch (280) between 45 ° and 110 ° and preferably 80 °.
A separator (2 ') as listed above with respect to the second aspect of the invention, wherein said other longitudinal parts have a depth between one tenth and half of that of said at least one longitudinal part (612) and preferably have a depth of one third that of said at least a longitudinal part (612).
A separator (2 ') as listed above with respect to the second aspect of the invention, wherein said at least one longitudinal part (612) is located on an opposite side of the housing member (72') to said first outlet opening (10 ') of the accommodation (4', 70 ').
A separator (2 ') as listed above with respect to the second aspect of the invention, wherein said at least one longitudinal part (612) opens into a channel (272) defined by the housing member (72') to direct fluid for said first outlet opening (10 ') of the housing (4', 70 ').
A separator (2 ') as related above with respect to the second aspect of the invention, wherein said at least one longitudinal part (612) is an entrance (282) for said channel (272), said channel (272) comprising the elements ( 276, 278) at said channel inlet (282) which, in use, are aligned with the direction of fluid flowing into said channel inlet (282).
A separator (2 ') as related above with respect to the second aspect of the invention, wherein said elements (276, 278) are curved at said channel inlet (282) and progressively rectifies in a downstream direction for said first outlet opening (10 ') of the housing (4', 70 ').
A separator (2 ') as listed above with respect to the second aspect of the invention, wherein said elements (276, 278) comprise opposite side walls defining said channel (272).
A separator (2 ') as listed above with respect to the second aspect of the invention, wherein the housing member (72') is located adjacent an end member (86 ') of the rotor unit (78', 84 ', 86 '), said region (606) and channel (272) being defined between the extreme member (86') and the housing member (72 ').
A separator (2 ') as listed above with respect to the second aspect of the invention, wherein the distance between the housing member (72') and said end member (86 ') of the rotor unit (78', 84 ', 86 ') is greater in a part of said region (606) than in other parts thereof, a part thereby defining said channel (272) in the housing member (72').
A separator (2 ') as listed above with respect to the second aspect of the invention, wherein said channel (272) comprises a tubular part (270).
A third aspect of the present invention provides a gas cleaning separator (2 ') to separate a flowable mixture of substances of different densities, such as a gas and a liquid; the separator (2 ') comprising:
a housing (4 ') defining an internal space, a rotor unit (78', 84 ') to grant a rotary movement over said mixture of substances, the rotor unit (78', 84 ') being located in said internal space and rotating around a geometric axis (64 ') relative to the housing (4'), in which the rotor unit comprises an inlet (600) to receive said mixture of substances, an outlet (604) from which said substances are ejected of the rotor unit during use, and a flow path (602) to provide fluid communication between the inlet (600) and the outlet (604), in which the outlet (604) is positioned more radially out of said geometry axis ( 64 ') than the entrance (600); and a housing member (72 ') defining a region (606) for receiving fluid ejected from the rotor unit (781, 84') and directing said fluid to a first outlet opening (10 ') of the housing (4', 70 ');
characterized in that said region (606) comprises a channel (272) extending from a part of a perimeter edge (274) of the housing member (72 '), said part defining an entrance (282) for said channel (272) .
Other details of the invention are provided in a separator as listed below:
a separator (2 ') as listed above with respect to the third aspect of the invention, wherein said channel (272) comprises elements (276, 278) at said channel entrance (282) which, in use, are aligned with the direction of the fluid flowing into said channel inlet (282).
A separator (2 ') as listed above with respect to the third aspect of the invention, wherein said elements (276, 278) are curved at said channel entrance (282) and progressively rectifies in a downstream direction towards said first opening (10 ') from the housing (4', 70 ').
A separator (2 ') as listed above with respect to the third aspect of the invention, wherein said elements (276, 278) comprise opposite side walls defining said channel (272).
A separator (2 ') as listed above with respect to the third aspect of the invention, wherein said channel inlet (282) is located on an opposite side of the housing member (72') to said first outlet opening (10 ') of the accommodation (4 ', 70').
A separator (2 ') as listed above with respect to the third aspect of the invention, wherein said perimeter part defining the channel entrance (282) has a partially circular shape extending through an arc (280) between 45 ° and 110 ° and preferably 80 °.
A separator (2 ') as listed above with respect to the third aspect of the invention, wherein the housing member (72') is located adjacent an end member (86 ') of the rotor unit (78', 84 ', 86 '), said region (606) and channel (272) being defined between the extreme member (86') and the housing member (72 ').
A separator (2 ') as listed above with respect to the third aspect of the invention, wherein the distance between the housing member (72') and said end member (86 ') of the rotor unit (78', 84 ', 86 ') is greater in one part of said region (606) than in the other part thereof, a part thereby defining said channel (272) in the housing member (72').
A separator (2 ') as listed above with respect to the third aspect of the invention, wherein said channel (272) comprises a tubular part (270).
A fourth aspect of the present invention provides a gas cleaning separator (2 ') to separate a flowable mixture of substances of different densities, such as a gas and a liquid; the separator (2 ') comprising:
a rotor unit (78 ', 84') to grant a rotary movement over said mixture of substances, the rotor unit (78 ', 84') being located in said internal space and rotating around a geometric axis (64 ' ) relative to the housing (4 '), in which the rotor unit comprises an inlet (600) for receiving said mixture of substances, an outlet (604) from which said substances are ejected from the rotor unit during use, and a path flow (602) to provide fluid communication between the input (600) and the output (604), where the output (604) is positioned more radially out of said geometry axis (64 ') than the input (600) ; and a housing member (72 ') defining a region (606) for receiving fluid ejected from the rotor unit (78', 84 ') and directing said fluid to a first outlet opening (10') of the housing (4 ', 70 '), characterized by the fact that said region (606) comprises a channel (272) having elements (276, 278) in an inlet (282) for said channel (272) which, in use, are aligned with the direction of the fluid flowing into said channel entrance (282).
Other details of the invention are provided in a separator as listed below:
A separator (2 ') as listed above with respect to the fourth aspect of the invention, wherein said channel (272) extends from part of a perimeter edge (274) of the housing member (72'), said part defining the input (282) for said channel (272).
A separator (2 ') as listed above with respect to the fourth aspect of the invention, wherein said elements (276, 278) are curved at said channel entrance (282) and progressively ground in a downstream direction for said first outlet opening (10 ') of the housing (4', 70 ').
A separator (2 ') as listed above with respect to the fourth aspect of the invention, wherein said elements (276, 278) comprise opposite side walls defining said channel (272).
A separator (2 ') as listed above with respect to the fourth aspect of the invention, wherein said channel inlet (281) is located on an opposite side of the housing member (72') for said first outlet opening (10 ') of the accommodation (4 ', 70').
A separator (2 ') as listed above with respect to the fourth aspect of the invention, wherein said perimeter part defining the channel entrance (282) has a partially circular shape extending through an arc (280) between 45 ° and 110 ° and preferably 80 °.
A separator (2 ') as listed above with respect to the fourth aspect of the invention, wherein the housing member (72') is located adjacent an end member (86 ') of the rotor unit (78', 84 ', 86 '), said region (606) and channel (272) being defined between the extreme member (86') and the housing member (72 ').
A separator (2 ') as listed above with respect to the fourth aspect of the invention, wherein the distance between the housing member (72') and said end member (86 ') of the rotor unit (78', 84 ', 86 ') is greater in a part of said region (606) than in other parts thereof, a part thereby defining said channel (272) of the housing member (72').
A separator (2 ') as listed above with respect to the fourth aspect of the invention, wherein said channel (272) comprises a tubular part (270).
A fifth aspect of the present invention provides a gas cleaning separator (2 ') to separate a flowable mixture of substances of different densities, such as a gas and a liquid; the separator (2 ') comprising:
a housing (4 ', 70') defining an internal space, a rotor unit (78 ', 84') to provide a rotary movement in said mixture of substances, the rotor unit (78 ', 84') being located in said internal and rotating space around a geometrical axis (64 ') relative to the housing (4', 70 '), wherein the rotor unit comprises an inlet (600) to receive said mixture of substances, an outlet (604) of which said substances are ejected from the rotor unit during use, and a flow path (602) to provide fluid communication between the inlet (600) and the outlet (604), in which the outlet (604) is positioned more radially to outside said geometric axis (64 ') than the entrance (600); and a housing member (72 ') defining a region (606) for receiving fluid ejected from the rotor unit (78', 84 ') and directing said fluid to a first outlet opening (10') of the housing (4 ', 70 ');
characterized by the fact that the housing member (72 ') is provided with means (264) to secrete an inlet to said region (606) of the fluid which, in use, recirculates back to said inlet after having drained beyond said inlet.
Other details of the invention are provided in a separator as listed below:
A separator (2 ') as listed above with respect to the fifth aspect of the invention, wherein said segregation means (264) comprises a wall.
A separator (2 ') as listed above with respect to the fifth aspect of the invention, wherein said wall extends from one side downstream of said region entry (606) in a downstream direction with respect to said fluid flow having , in use, past said region entry (606).
A separator (2 ') as listed above with respect to the fifth aspect of the invention, wherein said wall is separated from said housing (4') ·
A separator (2 ') as listed above with respect to the fifth aspect of the invention, wherein said wall comprises a free end (608).
A separator (2 ') as listed above with respect to the fifth aspect of the invention, wherein said free end (608) is moved away (456) from said housing (4', 70 ') in an axial direction by an axial distance between 2 mm and 200 mm and preferably over a distance of 14 mm.
A separator (2 ') as related above with respect to the fifth aspect of the invention, wherein said free end (608) is moved away from said housing (4', 70 ') in a direction perpendicular to said axial direction by a distance less than that dictates axial distance.
A separator (2 ') as listed above with respect to the fifth aspect of the invention, wherein said wall defines a closed circuit.
A separator (2 ') as listed above with respect to the fifth aspect of the invention, wherein said wall defines a frustoconic shape.
A separator (2 ') as listed above with respect to the fifth aspect of the invention, wherein said frusto-conical shape has a longitudinal geometric axis coinciding with said geometric axis (64') of rotation.
A separator (2 ') as listed above with respect to the fifth aspect of the invention, in which said frusto-conical shape diverges in a downstream direction with respect to said fluid flow having, in use, past said region entry (606) .
A spacer (2 ') as listed above with respect to the fifth aspect of the invention, wherein the housing member (72') comprises means (266) for supporting the housing member (72 ') relative to the housing (4', 70 '), the support means (266) being located downstream of the segregation means (264) with respect to said fluid flow having, in use, past said region inlet (606).
A separator (2 ') as listed above with respect to the fifth aspect of the invention, wherein the support means (266) is a wall defining a closed circuit.
A separator (2 ') as listed above with respect to the fifth aspect of the invention, wherein said wall has a cylindrical shape.
A separator (2 ') as listed above with respect to the fifth aspect of the invention, wherein said wall has a longitudinal geometric axis coinciding with said geometric axis (64') of rotation.
A separator (2 ') as listed above with respect to the fifth aspect of the invention, in which at least one opening (454) is provided in said wall at a junction between said wall and the housing ((4', 70 ').
A separator (2 ') as listed above with respect to the fifth aspect of the invention, further comprising a second outlet opening of the housing (4', 70 '), wherein said support means (266) is located in a flow path of fluid between the second outlet opening and said segregation means (264).
A separator (2 ') as listed above with respect to the fifth aspect of the invention, in which the second outlet opening is arranged concentrically with said geometric axis (64') of rotation.
A separator (2 ') as listed above with respect to the fifth aspect of the invention, in which said segregation means (264) is positioned in the housing (4', 70 '), so that, in use, the fluid flowing beyond said region inlet (606) flows on one side of said segregating medium (264) and said recirculating fluid flows on the other side of said segregating medium (264).
A separator (2 ') as listed above with respect to the fifth aspect of the invention, in which an outlet passage (211) extends between the housing member (72') and the housing (4 ', 70') for transport fluid from said region (606) to the outside of the housing (4 ', 70') through said outlet opening (10 '), the exterior of said outlet passage (211) being removed from the housing (4', 70 ') ) so that the fluid is free to flow around the entire outer perimeter of said outlet passage (211).
A separator (2 ') as listed above with respect to the fifth aspect of the invention, wherein said outlet passage (211) is separated from the housing member (72') and the housing (4 ', 70').
A sixth aspect of the present invention provides a gas cleaning separator (2 ') to separate a mixture of flowable substances of different densities, such as a gas and liquid, the separator (2') comprising:
a housing (4 ') defining an internal space, an opening to allow the flow of a fluid along a flow path between the exterior of said housing (4') and said internal space, and a shoulder (6 ') raising from the housing (4 ') and surrounding this opening;
characterized in that the shoulder (6 ') comprises a curved surface (221) extending into the opening.
Other details of the invention are provided in a separator as listed below:
A separator (2 ') as listed above with respect to the sixth aspect of the invention, in which said curved surface (221) forms a closed circuit around the opening and extends into the opening in order to reduce the opening area, when moving through said opening from the outside of said housing (4 ') towards said internal space.
A separator (2 ') as listed above with respect to the sixth aspect of the invention, wherein said curved surface (221) describes a partially circular line when viewed in a cross section taken through a plane coinciding with a longitudinal geometric axis (64' ) through said opening.
A separator (2 ') as listed above with respect to the sixth aspect of the invention, wherein the shoulder (6') comprises a generally cylindrical wall (217), a free end of which is provided with a circumferential edge (219) that forms the curved surface (221).
A separator (2 ') as listed above with respect to the sixth aspect of the invention, further comprising a nipple (22') connectable to the shoulder (6 '), so that an internal surface (216) of the nipple (22') matches with the curved surface (221) of the shoulder (6 ') to provide a curved surface for the flow path.
A separator (2 ') as listed above with respect to the sixth aspect of the invention, in which the inner nipple surface (216) meets the curved surface (221) at an edge (229) of the shoulder (6') and, in this meeting point, is oriented tangentially to the curved surface (221).
A separator (2 ') as listed above with respect to the sixth aspect of the invention, wherein the nipple (22') further comprises a curved wall (235) configured to contact the curved surface (221) of the shoulder (6 ').
A spacer (2 ') as listed above with respect to the sixth aspect of the invention, wherein the nipple (22') is connectable to the shoulder (6 ') in any rotational orientation.
A separator (2 ') as listed above with respect to the sixth aspect of the invention, wherein the nipple (22') is connectable with the shoulder (6 ') by turning welding.
A seventh aspect of the present invention provides a method for assembling a gas cleaning separator (2 '), the method comprising the step of connecting a nipple (22') to a boss (6 ') by rotating welding; the separator being as stated above with respect to the sixth aspect of the present invention.
A sixth aspect of the present invention provides a gas cleaning separator (2 ') to separate a flowable mixture of substances of different densities, such as a gas and liquid, the separator (2') comprising:
a housing (4 ') defining an internal space, a rotor unit (78', 84 ') to provide a rotary movement in said mixture of substances, the rotor unit (78', 84 ') being located in said internal space and rotating about a geometric axis (64 ') relative to the housing (4'), in which the rotor unit comprises an inlet (600) to receive said mixture of substances, an outlet (604) from which said substances are ejected of the rotor unit during use, and a flow path (602) to provide fluid communication between the input (600) and output (604), in which the output (604) is positioned more radially outward from said axis geometric (64 ') than the entrance (600);
a housing member (72 ') defining a region (606) for receiving fluid ejected from the rotor unit (78', 84 ') and directing said fluid to a first outlet opening (10') of the housing (4 ', 70 ');
characterized by the fact that an outlet passage (211) extends between the housing member (72 ') and the housing (4', 70 ') to transport fluid from said region (606) to the outside of the housing (4', 70 ') through said outlet opening (10'), in which the exterior of said outlet passage (211) is removed from the housing (4 ', 70'), so that the fluid is free to flow around the entire external perimeter of said exit passage (2H).
Other details of the invention are provided in a separator as listed below:
A separator (2 ') as listed above with respect to the eighth aspect of the invention, wherein the housing member (72') is provided with means (264) to secrete an inlet to said region (606) of fluid which, in use , recirculating back to said entrance after draining beyond said entrance, in which said exit passage (211) extends from said means of segregation (264).
A separator (2 ') as listed above with respect to the eighth aspect of the invention, wherein said segregation means (264) comprises a wall, said wall preferably comprising a free end (608) and being removed from said housing (4', 70 ').
A separator (2 ') as listed above with respect to the eighth aspect of the invention, wherein said outlet passage (211) is separated from the housing member (72') and the housing (4 ', 70').
A ninth aspect of the present invention provides a gas cleaning separator (2 ') to separate a flowable mixture of substances of different densities, such as a gas and liquid, the separator (2') comprising:
a housing (4 ') defining an internal space, a rotor unit (78', 84 ') to provide a rotary movement in said mixture of substances, the rotor unit (78', 84 ') being located in said internal space and rotating around a geometry axis (64 ') relative to the housing (4'), in which the rotor unit comprises an inlet (600) for receiving said mixture of substances, a first outlet (604) of which said substances are ejected from the rotor unit during use, and a first flow path (602) to provide fluid communication between the first inlet (600) and first outlet (604), in which the first outlet (604) is positioned more radially outward from said geometric axis (64 ') than the first entry (600); and a housing member (72 ') located adjacent to the rotor unit (78', 84 '), the housing member and the rotor unit being spaced apart in order to provide a first region (606) between them in a first side of the housing member (72 '), said first region (606) defining a first flow path from fluid to fluid ejected from the rotor unit (78', 84 '); the accommodation member (72 ') also being removed from the accommodation (4') in order to provide a second region between them on a second side of the accommodation member (72 '), said second region (614) defining a second way of fluid flow into the fluid ejected from the rotor unit (78 ', 84'), characterized by the fact that the rotor unit (78 ', 84') comprises a second inlet (618) which opens into said second region (614) of said second side of the housing member (72 '), a second outlet (620) positioned more radially outward from said geometric axis (64') than the second inlet (618), and a second flow path (616) to provide fluid communication between the second input (618) and the second output (620).
Other details of the invention are provided in a separator as listed below:
A separator (2 ') as listed above with respect to the ninth aspect of the invention, wherein said second outlet (620) opens into a fluid passageway providing fluid communication between said first outlet (604) and said first and second regions (606, 614).
A separator (2 ') as listed above with respect to the ninth aspect of the invention, wherein said second outlet (620) opens in a location that, with respect to a flow of said substances ejected from said first outlet (604) during use, is downstream of said first exit (604) and upstream of said first and second regions (606, 614).
A separator (2 ') as listed above with respect to the ninth aspect of the invention, wherein the second flow path (616) comprises a space between the first and second members (86', 240) of the rotor unit, each comprising a disk-shaped part, the two members (86 ', 240) being centered on said geometric axis (64').
A separator (2 ') as listed above with respect to the ninth aspect of the invention, wherein the disk shaped parts of said members (86', 240) each have a radially outer edge of a substantially circular shape, the two members ( 86 ', 240) being positioned concentrically with each other.
A separator (2 ') as listed above with respect to the ninth aspect of the invention, in which at least one elongated element (298) is located in said space between the first and second members (86', 240), in order to move fluid located in said space outwardly in relation to said geometric axis (64 ') when, in use, the rotor unit is rotated about said geometric axis (64').
A separator (2 ') as listed above with respect to the ninth aspect of the invention, wherein the or each elongated element (298) extends radially along the second flow path (616).
A separator (2 ') as listed above with respect to the ninth aspect of the invention, wherein the or each elongated element (298) consists of one of the first and second members (86', 240) and contacts the other of the first and second members (86 ', 240).
A separator (2 ') as listed above with respect to the ninth aspect of the invention, wherein said disk-shaped part of each member (86', 240) is frusto-conical.
A separator (2 ') as listed above with respect to the ninth aspect of the invention, wherein said second flow path (616) comprises a frusto-conical shape.
A separator (2 ') as listed above with respect to the ninth aspect of the invention, wherein said first flow path (602) comprises a frusto-conical shape.
A separator (2 ') as listed above with respect to the ninth aspect of the invention, wherein the second inlet (618) of said second flow path (616) comprises an annular shape centered on said geometric axis (64').
A separator (2 ') as listed above with respect to the ninth aspect of the invention, wherein the second flow path (616) extends through an opening in the housing member (72') between said first and second sides of the member accommodation (72 ').
A separator (2 ') as listed above with respect to the ninth aspect of the invention, wherein the second inlet (618) of said second flow path (616) is defined by a generally cylindrical wall (300).
A separator (2 ') as related above with respect to the ninth aspect of the invention, in which a space is provided between a part of the housing member (72') defining said opening therein and a first part (300) of the rotor unit defining at least part of said second flow path (616) and wherein another part (304) of the rotor unit extends from said first part (300) in order to cover said space.
A separator (2 ') as listed above with respect to the ninth aspect of the invention, wherein said other part (304) is located on said second side of the housing member (72').
A separator (2 ') as listed above with respect to the ninth aspect of the invention, wherein said other part (304) extends from the second entry (618).
A separator (2 ') as listed above with respect to the ninth aspect of the invention, wherein said other part (304) has an annular shape.
A separator (2 ') as listed above with respect to the ninth aspect of the invention, wherein said other part (304) has an outer circular perimeter edge of a diameter greater than the diameter of said opening of the housing member (72') .
A separator (2 ') as listed above with respect to the ninth aspect of the invention, wherein said other part (304) is planar and oriented in a plane to which said geometric axis (64') is perpendicular.
A separator (2 ') as listed above with respect to the ninth aspect of the invention, wherein a surface defining the second flow path (616) and extending from the second inlet (618) has a more radially outermost part (302) relative said geometric axis (64 ') which converges with said geometric axis (64') when moving along said second flow path (616) from the second inlet (618) towards the second outlet (620).
A separator (2 ') as listed above with respect to the ninth aspect of the invention, wherein said radially outermost part (302) of said second flow path surface has a frusto-conical shape.
A separator (2 ') as related above with respect to the ninth aspect of the invention, wherein said frusto-conical shape of said radially outermost part (302) has a central longitudinal axis coinciding with said axis of rotation (64') .
A tenth aspect of the present invention provides a gas cleaning separator (2 ') to separate a flowable mixture of substances of different densities, such as a gas and liquid; the separator (2 ') comprising:
a housing (4 ’, 70’) defining an internal space.
a rotor unit (78 ', 84') for granting a rotary movement over said mixture of substances, the rotor unit (78 ', 84') being located in said internal space and rotating around a geometric axis (64 ' ) relating to the housing (4 ', 70'), wherein the rotor unit comprises an inlet (600) for receiving said mixture of substances, an outlet (604) from which said substances are ejected from the rotor unit during use, and a flow path (602) to provide fluid communication between the input (600) and the output (604), in which the output (604) is positioned more radially out of said geometry axis (64 ')] than the input (600), and the rotor unit (78 ', 84') further comprising a rotary axis (78 ') coinciding with said geometry axis (64') and fixed in said housing (4 ', 70'), in which a the first extreme part of the rotating axis (78 ') extends through said housing (4', 70 ') to an outward position said housing (4 ', 70') and a fluid passage (92 ') extends axially through the rotating axis (78') and has an opening positioned externally to said housing (4 ', 70');
characterized by the fact that the rotor unit (78 ', 84') additionally comprises flow control means (364, 366) to control the fluid inlet for said shaft fluid passage (92 ') from the outside of said housing ( 4 ', 70'), in which the flow control means (364, 366) comprises means for granting, on the fluid entering said passage (92 '), a rotational movement along a radially external path of the passage of shaft fluid (92 '), a rotary movement along a radially outward path from the shaft fluid passage (92').
Further details of the invention are provided in a separator as listed below:
A separator (2 ') as listed above with respect to the tenth aspect of the invention, wherein said rotary movement is centered on said rotational unit (78') axis of rotation (78 ', 84').
A separator (2 ') as listed above with respect to the tenth aspect of the invention, wherein the passage (92') is coincident with said rotary unit axis (64 ') of rotation (78', 84 ').
A separator (2 ') as related above with respect to the tenth aspect of the invention, wherein said means for granting a rotary movement in said fluid comprises at least one fluid path (366) positioned radially outwardly from said geometric axis ( 64 ') of rotation of the rotor unit (78', 84 ').
A separator (2 ') as listed above with respect to the tenth aspect of the invention, wherein said means of granting a rotary movement over the fluid comprises a member (364) removed from said opening of the shaft fluid passage (92'), wherein the at least one fluid path (366) is an opening extending through said member (364).
A separator (2 ') as listed above with respect to the tenth aspect of the invention, in which four of said fluid paths (366) are positioned equidistant along the circumference of a circle centered on said geometric axis (64').
A separator (2 ') as listed above with respect to the tenth aspect of the invention, wherein said member (364) is planar and oriented with said geometric axis (64') perpendicular thereto.
A separator (2 ') as listed above with respect to the tenth aspect of the invention, wherein the flow control means further comprises at least one drain opening (368) positions the most radially outward from said geometric axis (64 ') than the or each flow path (366).
A separator (2 ') as listed above with respect to the tenth aspect of the invention, wherein the flow control means (364, 366) and at least part of a turbine (88') to drive the rotation of the rotor unit ( 78 ', 84') be a unitary component.
A separator (2 ') as listed above with respect to the tenth aspect of the invention, wherein a second end of the rotary axis (78') distal to the first end part is mounted in the housing (4 ', 70').
A separator (2 ') as listed above with respect to the tenth aspect of the invention, wherein the fluid passage (92') extends between the first and second extreme parts of the rotary axis (78 '), in order to provide communication flow through them between the exterior and interior of the housing (4 ', 70').
A separator (2 ') as listed above with respect to the tenth aspect of the invention, wherein the fluid passage (92') is in fluid communication with a support (50 ') through which said outer peripheral surface of the rotary axis (78' ) is mounted to the housing (4 ', 70').
A separator (2 ') as listed above with respect to the tenth aspect of the invention, wherein the fluid passage (92') is in fluid communication with said inlet (600) of the rotor unit.
A tenth aspect of the present invention provides a method for assembling a gas cleaning separator (2 ') to separate a flowable mixture of substances of different densities, such as a gas and liquid; the separator (2 ') comprising:
a housing (4 ', 70') defining an internal space and having an opening (8 ') to provide fluid communication between said internal space and the exterior of said housing (4', 12 '), and a first fluid flow ( 22 ') sealed around said opening (8') and in fluid communication with it to transport fluid through said passage (22 ') and opening (8') between said internal space and the outside of said housing (4 ' , 12 ');
characterized by the fact that the method for assembling said separator (2 ') comprises the step of:
joining the housing material (4 ', 12') and fluid flow passage (22 ') to each other along a closed circuit formed by an intersection of contact surfaces of the housing (4', 12 ') and passage of fluid flow (22 ').
Other details of the invention are provided in a method as narrated below:
A method as listed above with respect to the eleventh aspect of the invention, wherein said closed circuit is circular in shape.
A method as described above with respect to the eleventh aspect of the invention, in which said joining step comprises rotating the housing (4 ', 12') and first fluid flow (22 ') in relation to each other, while said surfaces are in contact with each other.
A method as narrated above with respect to the eleventh aspect of the invention, wherein said relative rotation of the housing (4 ', 12') and fluid flow passage (22 ') is stopped with the housing (4', 12 ') and the fluid flow passage (22 ') is stopped with the housing (4', 12 ') and the flow passage 22' arranged in a required position relative to each other in order to allow said contact surfaces to come together .
A method as narrated above with respect to the eleventh aspect of the invention, in which said joining step comprises welding by turning said contact surfaces together.
A method as described above with respect to the eleventh aspect of the invention, wherein said joining step comprises rotating applying adhesive to at least one of said adjoining surfaces.
A method as narrated above with respect to the eleventh aspect of the invention, wherein said joining step comprises ultrasonic welding or vibration welding of said contact surfaces.
A method as narrated above with respect to the eleventh aspect of the invention, wherein the first fluid flow (22 ') is a nipple comprising an open end, distal to said contact surface, for subsequent connection with another first fluid flow, such as a hose.
A twelfth aspect of the present invention provides a gas cleaning separator (2 ') to separate a flowable mixture of substances of different densities, such as a gas and liquid; the separator (2 ') comprising:
a housing (4 ', 12') defining an internal space and having an opening (8 ') in it to provide fluid communication between said internal space and the exterior of said housing (4', 12 ') and a first fluid flow (22 ') sealed around said opening (8') and in fluid communication with it to transport fluid through said passage (22 ') and opening (8') between said internal space and the outside of said housing (4 ', 12');
characterized by the fact that the housing material (4 ', 12') and the first fluid flow (22 ') are joined along a closed circuit formed by an intersection of contact surfaces of the housing (4', 12 ' ) and first fluid flow (22 ').
Other details of the invention are provided in a separator as listed below:
A separator (2 ') as listed above with respect to the twelfth aspect of the invention, wherein said closed circuit is circular in shape.
A separator (2 ') as related above with respect to the twelfth aspect of the invention, wherein said joining is made by rotating the housing (4', 12 ') and the fluid flow passage (22') in relation to each other , while said their surfaces are in contact with each other.
A separator (2 ') as listed above with respect to the twelfth aspect of the invention, wherein said relative rotation of the housing (4', 12 ') and fluid flow passage (22') is stopped with the housing (4 ', 12') and the flow passage (22 ') arranged in a required position with respect to each other, in order to allow said contact surfaces to come together.
A separator (2 ') as related above with respect to the twelfth aspect of the invention, wherein said joining is made by welding by turning said contact surfaces together.
A separator (2 ') as listed above with respect to the twelfth aspect of the invention, wherein said joining is done by applying adhesive to at least one of said contact surfaces.
A separator (2 ') as listed above with respect to the twelfth aspect of the invention, wherein said joining is made by ultrasonic welding or vibration welding of said contact surfaces with each other.
A separator (2 ') as listed above with respect to the twelfth aspect of the invention, wherein the fluid flow passage (22') is a nipple comprising an open end, distal to said contact surface, for subsequent connection with another first flow of fluid, such as a hose.
A thirteenth aspect of the present invention provides a method for assembling a gas cleaning separator (2 ') to separate a flowable mixture of substances of different densities, such as a gas and a liquid; wherein the separator (2 ') comprises:
a housing (4 ', 12') comprising first and second separate parts (4 ', 70'), the first housing part (4 ') having an alignment surface (632) against which a reference surface (630) the second housing part (70 ') aligns in order to define an internal space of the housing (4', 70 '); and a rotor unit (78 ', 84') located in said internal space and rotating around a geometric axis (64 ') of the first housing part (4') relative to the housing (4 ', 70'), the rotor unit (78 ', 84') comprising a rotary axis (78 ') rotatably mounted on the first housing part (4') by means of a support unit (50 ') and rotatably mounted on the second housing part (70 ');
characterized by the fact that the method for assembling said separator (2 ’) comprises the steps of:
rotatably fix the rotary axis (78 ') in the second housing part (70') in a predetermined position with respect to said reference surface (630) in which said predetermined position coincides with said geometric axis (64 ') when the surface reference (630) of the second housing part (70 ') is in alignment with said alignment surface (632) of the first housing part (4');
locating the support unit (50 ') on a template (500), where the template (500) comprises a reference surface (634) for alignment with the alignment surface (632) of the first housing part (4') and means (512) for receiving said support unit (50 ') in a position in relation to the reference surface (634) of the template (500), so that the support unit (50') is received by the template (500 ) in a position in relation to the reference surface (634) of the template that coincides with said geometric axis (64 ') when the reference surface (634) of the template (500) is in register with said alignment surface (632) the first housing part (4 ');
locating the reference surface (634) of the template (500) in alignment with said alignment surface (632) of the first housing part (4 '); and securing the support unit (50 ') to the first housing part (4').
Other details of the invention are provided in a method as listed below;
A method as listed above with respect to the thirteenth aspect of the invention, wherein the step of securing the support unit (50 ') comprises moving the receiving member (512) of the template (500) in an axial direction along said axis geometric (64 ') with respect to the first housing part (4'), while the reference surface (634) of the template (500) is in alignment with said alignment surface (632) of the first housing part (4 ') , the support unit (50 ') is thus brought into contact with the first housing part (4').
A method as listed above with respect to the thirteenth aspect of the invention, in which the receiving means (512) is moved in said axial direction with respect to the reference surface (634) of the template (500), in order to press the support (50 ') against the first housing part (4').
A method as listed above with respect to the thirteenth aspect of the invention, wherein the template (500) comprises means for allowing the movement of the receiving means (512) in an axial direction along said geometric axis (64 ') with respect to reference surface (634) of the template (500).
A method as listed above with respect to the thirteenth aspect of the invention, wherein the step of securing the support unit (50 ') comprises rotating the receiving means (512) of the template (500) around said geometric axis (64' ) with respect to the first housing part (4 ') while the reference surface (634) of the template (500) is in alignment with said alignment surface (632) of the first housing part (4').
A method as listed above with respect to the thirteenth aspect of the invention, wherein the step of securing the support unit (50 ') comprises welding the support unit (50') by rotation to the first housing part (4 ').
A method as listed above with respect to the thirteenth aspect of the invention, wherein the template (500) comprises means for allowing rotation of the receiving medium (512) with respect to the reference surface (634) of the template (500).
A fourteenth aspect of the present invention provides a gas cleaning separator (2 ') to separate a flowable mixture of substances of different densities, such as a gas and liquid, in which the separator (2') was assembled as described above with respect to the thirteenth aspect of the present invention.
A fifteenth aspect of the present invention provides a method for assembling a system comprising a gas cleaning separator (2 ') to separate a flowable mixture of substances of different densities, such as a gas and liquid, wherein the method comprises the steps of selecting a particular version of a first type of component (4 ') from a plurality of different versions of said first type of component (4'); and connecting said particular version of said first type of component (4 ') with a second type of component (12');
characterized in that said plurality of different versions of said first type of component (4 ') comprises common details (207, 211) for connecting said second type of component (12').
Other details of the invention are provided in a method as narrated below:
A method as described above with respect to the fifteenth aspect of the invention, further comprising the step of selecting a particular version of said second type of component (12 ') from a plurality of different versions of said second type of component (12').
A method as cited above with respect to the fifteenth aspect of the invention, further comprising the step of locating a third type of component between the first and second types of components (4 ', 12').
A method as mentioned above with respect to the fifteenth aspect of the invention, further comprising the step of selecting said third type of component from a plurality of different versions of said third type of component, wherein said plurality of different versions of said third type component comprises common details for connecting with said first and second types of components (4 ', 12').
A method as cited above with respect to the fifteenth aspect of the invention, wherein said first type of component comprises a rotor housing (4 '); said second type of component comprises a valve unit housing (12 ') and said third type of component comprises a thermal shield.
A method as cited above with respect to the fifteenth aspect of the invention, wherein said components are of said separator (2 ').
A method as cited above with respect to the fifteenth aspect of the invention, wherein said plurality of different versions of said first type of component (4 ') comprises other common details (6') for connection with a fourth type of component (22 ').
A method as mentioned above with respect to the fifteenth aspect of the invention, wherein said fourth type of component is a nipple (22 ').
A sixteenth aspect of the present invention provides a kit of parts to be mounted on a gas cleaning separator (2 ') to separate a flowable mixture of substances of different densities, such as a gas and liquid; wherein said kit of parts comprises a plurality of different versions of a first type of component (4 ') of said separator (2') for connecting with a second type of component (12 ') of said separator (2') and at least one version of said second type of component (12 '); characterized in that said plurality of different versions of said first type of component (4 ') comprises common details (207, 211) to connect with said second type of component (12'). Ideally, said plurality of different versions of said first type of component (4 ') comprises other common details (6') for connection with a third type of component (22 ').
A seventeenth aspect of the present invention provides a gas cleaning separator (2 ') to separate a flowable mixture of substances of different densities, such as a gas and liquid, wherein the separator (2') comprises:
a housing (4 ') defining an internal space;
a rotor unit (78 ', 84') to provide a rotary movement in said mixture of substances, the rotor unit (78 ', 84') being located in said internal space and rotating around a geometric axis (64 ' ) relating to accommodation (4 '); and a valve unit (14 ') for controlling a flow from an outlet (10') of said housing (4 ') of a separate substance from said mixture of substances, wherein said valve unit (14') comprises a valve arrangement located in an internal space defined by a valve unit housing (12 ') .;
characterized in that the valve unit housing (12 ') is separate from the rotor unit housing (4').
An eighteenth aspect of the present invention provides a gas cleaning separator (2 ') to separate a flowable mixture of substances of different densities, such as a gas and liquid, the separator (2') comprising;
a housing (4 ', 70') defining an internal space, a rotor unit located in said internal space and rotating around a geometric axis (64 ') in relation to the housing, and a housing member (72') fixed in said housing (4 ', 70'), in order to allow a flow of fluid on each side of the housing member (72 ') in which the fluid flowing on one side of said member (72') is directed by said member towards the exterior of said housing (4 ', 70') through a first exit opening (10 ') and said housing (4', 70 ');
characterized in that said fluid is directed through an outlet passage (211) connecting said housing member (72 ') to the exterior of the housing, the outlet passage (211) being sealed to at least one of the housing member (72 ') and housing (4', 70 ') by means of a sealing member provided around the outlet passage (211).
Other details of the invention are provided in a separator as mentioned below:
A separator (2 ') as mentioned above with respect to the eighteenth aspect of the invention, wherein said outlet passage (211) is moved away from said housing (4', 70 ').
A separator (2 ') as mentioned above with respect to the eighteenth aspect of the invention, wherein said outlet passage (211) is separated from the housing member (72') and sealed thereon by means of a sealing element ( 215).
A separator (2 ') as mentioned above with respect to the eighteenth aspect of the invention, wherein said outlet passage (211) is separated from the housing (4', 70 ') and sealed thereon by means of a sealing element (213 ).
A separator (2 ') as mentioned above with respect to the eighteenth aspect of the invention, wherein the or each sealing element for sealing said outlet passage (211) is provided on an external surface of said passage in contact with a shoulder defined by said surface.
A separator (2 ') as mentioned above with respect to the eighteenth aspect of the invention, wherein said outlet passage (211) is integral with a valve unit (14') located outside the housing (4 ', 70') to control a flow of fluid from the housing (4 ', 70').
A separator (2 ') as mentioned above with respect to the eighteenth aspect of the invention, wherein the or each sealing element is an O-ring seal.
A separator (2 ') as mentioned above with respect to the eighteenth aspect of the invention, wherein said outlet passage (211) is moved away from said housing (4', 70 ') in order to allow fluid, located between the member of accommodation (72 ') and said accommodation (4', 70 '), drain around its entire external perimeter.
A nineteenth aspect of the present invention provides a gas cleaning separator (2 ') to separate a flowable mixture of substances of different densities, such as a gas and a liquid; the separator (2 ') comprising:
a housing (4 ') defining an internal space, a rotor unit (78', 84 ') to grant a rotary movement over said mixture of substances, the rotor unit (78', 84 ') being located in said internal space and rotating about a geometry axis (64 ') relative to the housing (4'), wherein the rotor unit (78 ', 84') comprises an inlet (600) to receive said mixture of substances, an outlet (604 ) from which said substances are ejected from the rotor unit (78 ', 84') during use, and a flow path (602) to provide fluid communication between inlet 600 and outlet (604), in which outlet (604 ) is positioned more radially outwardly from said geometry axis (64 ') than the inlet (600) and where the rotor unit (78', 84 ') comprises a rotary axis (78') having a geometry axis coinciding with said axis (64 ') of rotation and a separating disc (82') mounted on the rotary axis (78 ') by means of an opening (252) which is provided in the separating disc (82 ');
characterized by the fact that the rotating axis (78 ') comprises at least one key (254) and the fact that the opening (252) of the separating disc (82') has a shape that corresponds to a cross section taken perpendicular to the axis geometric (64 ') through the rotary axis (78') and at least one key (254).
Other details of the invention are provided in a separator as mentioned below:
A separator (2 ') as mentioned above with respect to the nineteenth aspect of the invention, wherein the at least one key (254) is provided in a central hub (114') joined to the rotary axis (78 ').
A separator (2 ') as mentioned above with respect to the tenth aspect of the invention, in which three braces (254) are provided.
A separator (2 ') as mentioned above with respect to the tenth aspect of the invention, wherein the at least one key (254) comprises a tip part (352) providing a free end of the key (254) and a root part ( 350), radially into the tip part (352), the root part (250) having a greater circumferential dimension than the tip part (352).
A separator (2 ') as mentioned above with respect to the tenth aspect of the invention, in which the different circumferential dimensions of the root part (350) and the tip part (352) provide a step (354) on each side of the at least a key (254) at the junction between the root part (350) and the tip part (352).
A separator (2 ') as mentioned above with respect to the tenth aspect of the invention, in which the circumferential dimension of the root part (350) varies along an axial length of the at least one key (254).
A separator (2 ') as mentioned above with respect to the tenth aspect of the invention, wherein the separating disc (82') has a frusto-conical shape.
A separator (2 ') as mentioned above with respect to the tenth aspect of the invention, wherein the or each key extends axially along a length of the rotary axis (78').
Grip avoidance
A twentieth aspect of the present invention provides a gas cleaning separator (2 ') to separate a flowable mixture of substances of different densities, such as a gas and liquid; the separator (2) comprising:
a housing (4 ') defining an internal space, a rotor unit (78', 84 ') to grant a rotary movement over said mixture of substances, the rotor unit (78', 84 ') being located in said internal space and rotating about a geometry axis (64 ') relative to the housing (4'), wherein the rotor unit (78 ', 84') comprises an inlet (600) to receive said mixture of substances, an outlet (604 ) that said substances are ejected from the rotor unit during use, and a flow path (602) to provide fluid communication between the inlet (600) and the outlet (604), the rotor unit (78 ', 84') further comprising a rotary axis (78 ');
characterized in that said rotating axis (78 ') is provided with a coating of a plastic material along a length of said rotating axis (78') slidably receiving at least one component of said separator (2 ').
A separator (2 ') as mentioned above in relation to the twentieth aspect of the invention, wherein at least one of said components is of a metallic material.
A separator (2 ') as mentioned above in relation to the twentieth aspect of the invention, wherein at least one of said components is a helical spring.
A separator (2 ') as mentioned above with respect to the twentieth aspect of the invention, wherein at least one of said components is a support unit (50').
A separator (2 ') as mentioned above in relation to the twentieth aspect of the invention, wherein said rotating axis (78') receives two of said components in opposite extreme parts of said rotating axis (78 '), where each component is a helical spring (130 ', 96').
A separator (2 ') as mentioned above in relation to the twentieth aspect of the invention, in which each helical spring (130', 96 ') is compressed between the rotor unit (78', 84 ') and a different one of two units of support (50 ', 90') connecting the rotary axis (78 ') to the housing (4').
A separator (2 ') as mentioned above in relation to the twentieth aspect of the invention, wherein each helical spring (130', 96 ') is made of metallic material.
A separator (2 ') as mentioned above in relation to the twentieth aspect of the invention, wherein said rotary axis (78') is of a non-tempered material.
A separator (2 ') as mentioned above in relation to the twentieth aspect of the invention, wherein said material is non-tempered metal and, preferably, non-tempered steel.
A separator (2 ') as mentioned above in relation to the twentieth aspect of the invention, wherein the rotor unit (78', 84 ') comprises at least one element (114', 116 ', 254) extending from said rotary axis (78 '), wherein said element (114', 116 ', 254) is of the same material as said coating and formed integrally with it.
A separator (2 ') as mentioned above in relation to the twentieth aspect of the invention, wherein said coating and said at least one element (114', 116 ', 254) are injection molded on said rotary axis (78') and, thus, formed simultaneously with each other.
UA 3291
A twenty-first aspect of the present invention provides a gas cleaning separator (2 ') to separate a flowable mixture of substances of different densities, such as a gas and liquid; the separator (2 ') comprising:
a housing (4 ') defining an internal space, and a rotor unit (78', 84 ') to provide a rotary movement to said mixture of substances, the rotor unit (78', 84 ') being located in said space internal and rotatable around a geometric axis (64 ') relative to the housing (4'), in which the rotor unit comprises an inlet (600) to receive said mixture of substances, an outlet (604) of which said substances are ejected from the rotor unit during use, and a flow path (602) to provide fluid communication between the input (600) and the output (604), characterized by the fact that the separator (2 ') additionally comprises an electric motor (380 ) to rotate said rotor unit (78 ', 84') and a fluid passage through the electric motor (380) to receive, in use, a separate substance from said mixture of substances.
Other details of the invention are provided in a separator as listed below:
A separator (2 ') as listed above with respect to the twenty-first aspect of the invention, wherein said fluid passage through the electric motor (380) is defined at least in part by a rotor (382) and a stator (400) of the electric motor (380).
A separator (2 ') as mentioned above in relation to the twentieth aspect of the invention, wherein said fluid passage comprises a space between the rotor (382) and the stator (400) of the electric motor (380).
A separator (2 ') as mentioned above with respect to the twentieth aspect of the invention, wherein said rotor (382) is connected to the rotor unit (78', 84 ').
A separator (2 ') as mentioned above in relation to the twentieth aspect of the invention, in which electrical wires located in said fluid passage are sealed in an insulating material.
A separator (2 ') as mentioned above in relation to the twentieth aspect of the invention, wherein said insulating material is provided as a layer covering electrical wires of said stator (400).
A separator (2 ') as mentioned above in relation to the twentieth aspect of the invention, wherein said insulating material comprises an epoxy lacquer.
A separator (2 ') as mentioned above in relation to the twentieth aspect of the invention, wherein the electric motor comprises one or more electronic components sealed by said fluid passage through the electric motor (380).
A separator (2 ') as mentioned above with respect to the twentieth aspect of the invention, in which the separator (2') comprises a housing (384) in which the electric motor (380) is located.
A separator (2 ') as mentioned above in relation to the twentieth aspect of the invention, wherein said electric motor housing (384) is connected to and separable from the housing (4') in which the rotor unit (78 ', 84' ) is located.
A separator (2 ') as mentioned above in relation to the twentieth aspect of the invention, in which the electric motor housing (384) comprises a sealed fluid passage compartment and in which the electronic components (408) of the electric motor (380 ) are located.
A separator (2 ') as mentioned above in relation to the twentieth aspect of the invention, wherein said compartment has a generally annular shape or partially annular shape which, in the mounted separator (2'), is concentric with said rotor unit (78 ' , 84 ').
A separator (2 ') as mentioned above in relation to the twentieth aspect of the invention, wherein said compartment is included by said electric motor housing (384) and by a member (394) separate from said housing (384) and sealed therein.
A separator (2 ') as mentioned above in relation to the twentieth aspect of the invention, wherein said members (394) is of a generally annular or frusto-conical shape.
A separator (2 ') as mentioned above with respect to the twentieth aspect of the invention, wherein said member (394) is arranged concentrically with said rotor unit (78', 84 ').
A separator (2 ') as mentioned above in relation to the twentieth aspect of the invention, in which a radially internal part of said member (394) is sealed in said electric motor housing (384) along a closed circuit and a part radially outer part of said member (394) is sealed in said electric motor housing (384) along another closed circuit.
A separator (2 ') as mentioned above in relation to the twenty-first aspect of the invention, wherein said radially internal part of said member (394) is sealed in a generally cylindrical part (392) of said electric motor housing (384) inwardly from which, in the mounted separator, said rotor unit (78 ', 84') extends.
A separator (2 ') as mentioned above in relation to the twenty-first aspect of the invention, wherein said radially internal part of said member (394) defines an opening having a diameter less than or substantially equal to the innermost diameter of the stator (400) of the electric motor (380).
A separator (2 ') as mentioned above in relation to the twenty-first aspect of the invention, in which said member (394) is provided with at least one opening through which an electrical wire extends and in which said wire is sealed.
A separator (2 ') as mentioned above in relation to the twenty-first aspect of the invention, wherein said one or more components comprise one or more components to control the operation of the electric motor (380).
A separator (2 ') as mentioned above with respect to the twenty-first aspect of the invention, wherein said fluid passage spins in fluid communication with an outlet orifice (402) in the electric motor housing (384).
A separator (2 ') as mentioned above in relation to the twenty-first aspect of the invention, further comprising an electrical connector (412) for receiving an electrical wire providing electrical energy and / or control signals for the electric motor (380).
A separator (2 ') as mentioned above in relation to the twenty-first aspect of the invention, in which the electrical connector (412) is electrically connected to the electric motor (380) by means of one or more electrical components (408).
A separator (2 ') as mentioned above in relation to the twenty-first aspect of the invention, in which the electrical connector (412) is located in an opening extending through a part of a housing (384) of the separator (2').
A prior art ALFDEX ™ centrifugal separator, together with embodiments of the present invention, will now be described with reference to the accompanying drawings, in which:
Figure 1 is a cross-sectional perspective view of a prior art ALFEX ™ centrifugal separator;
Figure 2 is a cross-sectional view of the separator shown in Figure 1 in combination with a turbine housing;
Figure 3 is a cross-sectional perspective view of an input / output nipple for use with the separator shown in Figure 1;
Figure 4 is a cross-sectional side view of a mold for the inlet / outlet nipple shown in Figure 3;
Figure 5 is a perspective view of a separator rotor shown in Figure 1;
Figure 6 is a perspective view in cross section of the rotor shown in Figure 5;
Figure 7 is an extreme perspective view of the rotor shown in Figure 5, in which an upper rotor disk is shown removed from a rotating axis of said rotor, so that the rotating axis is shown in cross section.
Figure 8 is a side view in cross section of the separator shown in Figure 1, in which the separate gas and oil flow paths are illustrated;
Figures 9 and 10 are side views in cross section of the separator shown in Figure 1, in which a desirable oil flow path and an undesirable oil flow path are respectively illustrated.
Figure 11 is a top perspective view of a separator housing insert shown in Figure 1.
Figure 12 is a side perspective view of the housing insert shown in Figure 11, in which part of an outer flap of the housing insert has been removed in order to more clearly show an undesirable flow path of separate oil droplets.
Fig. 13 is a side perspective view of a first separator according to the present invention, in which a separator housing is shown in cross section, in order to illustrate a rotor unit and housing insertion located within said housing ;
Figure 14 is an enlarged view of the area surrounded by line A shown in Figure 13;
figure 15 is a perspective side view in cross section of the first embodiment of the present invention, as shown in figure 13;
Figure 16 is a cross-sectional side view of an input nipple connected to an input of the first embodiment;
Figure 17 is a perspective view of the entry and entry nipple of Figure 16 separated from each other;
Figure 18 is a top perspective view in cross section of the first embodiment of Figure 13, in which the cross section is taken through a parallel plane with a support plate of the first embodiment and passing through line 18 - 18 of Figure 15;
Figure 19 is a side view in perspective in cross section of a second embodiment, in which the second embodiment differs from the first embodiment in that a cover of plastic material is provided on the upper end of the rotor unit. ;
Figure 20 is a side perspective view in cross section of the first embodiment shown in Figure 13;
Figure 21 is a top perspective view of an upper rotor disk and rotary axis of the first embodiment shown in Figure 13;
Figure 22 is a velocity flow diagram showing the velocity of the inlet fluid relative to a guide surface provided on the upper rotor disk shown in Figure 21;
Figure 23 is a base perspective view of the upper rotor disc and rotary axis shown in Figure 21;
Figure 24 is a base perspective view of one of a plurality of separating discs for slidably locating on the rotary axis shown in Figures 21 and 23;
Figure 25 is a base perspective view of the separating disk shown in Figure 24 being slidably located on the rotating axis shown in Figures 21 and 23;
Figure 26 is a perspective view of a vane disc and associated end plate located above a housing insert which, in turn, is located on a support plate of the first embodiment shown in Figure 13;
Figure 27 is a side perspective view of a plurality of a separating disk located on the rotating axis of Figures 21 and 23, wherein said disks and axis are assembled with the components shown in Figure 26;
Figure 28 is a top perspective view of a housing insert of the first embodiment shown in Figure 13, where the housing insert is shown in isolation from other components, except for an oil spill guard located below said insertion.
Figure 29 is a partial perspective base view of the first embodiment shown in Figure 13, specifically showing a turbine wheel assembly of said embodiment;
Figure 30 is a side perspective view in partial cross-section of the turbine wheel unit shown in Figure 29;
Figure 31 is a side perspective view in partial cross-section of a turbine wheel unit shown in Figures 29 and 30;
Figure 32 is a base perspective view of the turbine wheel unit shown in Figure 31;
Figure 33 is a cross-sectional side view of the first embodiment shown in Figure 13;
Figure 34 is an enlarged cross-sectional side view of the first embodiment shown in Figure 13, in which the gas flow paths and oil droplets separated through the separator are illustrated;
Figure 35 is a cross-sectional side view of an electric motor drive arrangement from that shown in Figures above, in which the electric motor drive arrangement is shown in use with the prior art separator of Figure 1;
Figure 36 is a schematic view showing the modular nature of the separator system shown in Figure 13;
Figures 37 and 38 are views of a top support unit of the first embodiment being mounted on a rotation welding template.
Figure 39 is a side perspective view of a top support unit mounted on the rotating welding template of Figures 37e38;
Figure 40 is a perspective view of the unit shown in Figure 39, located inside a rotor housing of the first embodiment prior to rotation welding of a top support unit within said housing; and
Figure 41 is a perspective view of a top support unit having been fixed to an internal surface of the housing shown in Figure 40 by means of a rotation welding operation.
The prior art ALFDEX ™ separator will now be described with reference to Figures 1 to 12 of the accompanying drawings and with particular emphasis being placed on those aspects of this prior art separator that have been improved.
A number of views of an assembled prior art ALFDEX ™ separator 2 are shown in Figures 1, 2, 8, 9 and 10 of the accompanying drawings. It should be understood by those skilled in the art that the separator of the prior art 2 comprises a cylindrically shaped rotor housing 4, to receive numerous internal components that function to separate ventilated gas oil directed into said rotor housing 4.
One end of the cylindrical housing 4 is provided with a vertical annular shoulder 6, which defines a fluid inlet 8 for the separator 2. It must therefore be understood that the vented gas from a crankcase, and requiring the removal of oil from it, enters in the separator 2 via the fluid inlet 8.
An opening 10 in a cylindrical wall of the rotor housing 4 provides an outlet for clean gas to pass from inside the rotor housing 4 into another housing 12 associated with valve unit 14 (see Figure 1). The valve unit 14 comprises a valve arrangement for controlling the flow of clean gas from the separator 2. Details of the operation of the valve unit 14 will not be described here. However, as will be evident from Figure 1, the exterior of the rotor housing 4 is specifically designed to join with housing 12 of valve unit 14, so that the two housings 4, 12 combine to define an internal space between said housings 4, 12 suitable for receiving the internal components of the valve unit 14. The two housings 4, 12 are fastened together by conventional screw threaded fixings 16. We have therefore observed that a particular valve unit housing 12 can only be used with a specific rotor housing 4 having the necessary joining details.
Referring to Figure 1, it will be seen that the housing 12 of the valve unit 14 is provided with a raised annular shoulder 18, which defines a fluid outlet through which clean gas passes the separator 2. The annular shoulder 18 provided in the housing of the valve unit 12 is substantially identical to the annular shoulder 6 provided on the rotor housing 4. due to their similarity, the inlet and outlet lugs 6, 18 can interchangeably receive inlet / outlet nipples having the same interface profile. Such a nipple 22 having a 90 ° curve is shown, in cross section, in Figure 3. An end of the nipple 22 is provided with an annular collar 24 defining an annular recess 26. The annular recess 26 has a square edge profile and a diameter allowing it to receive an annular housing shoulder 6, 18 (which also has a square edge) in contact with it.
The interface formation of the shoulder 6 of the rotor housing 4 with an input nipple 28 can be seen with reference to Figure 2 of the accompanying drawings. It will be seen that the nipple 28 shown in Figure 2 has a different angle of curvature with the nipple 22 in Figure 3.
The entry / exit nipples are attached to their respective housings 4, 12, securing them over the housing shoulders 6, 18 using an annular washer 30, which presses down on the shoulder 24 of a nipple 22, 28 when fastening with screw thread 32 are screwed together with two threaded shoulders 34. The two shoulders 34 are vertical from the relevant housing 4, 12 and located on each side of the annular shoulder 6, 18. An O-ring seal 36 is located, trapped and compressed between the recess 26 and the housing shoulder 6, 18, in order to avoid an undesirable leakage of fluid from the interface between the inlet / outlet nipple and the respective housing (see Figure 2 with respect to the inlet nipple).
With more reference to nipples 22, 28 shown in Figures 3 and 2, respectively, a second end of the nipple (distal to the end provided with the interface profile) is provided with teeth or saws 38 on an external surface to grip a hose that , in use, is located on the second end of the nipple.
The fluid flow paths provided by the two nipples 22, 28 each comprise a curvature having an inner corner 40 substantially without a radius. In the separator of prior art 2, angled nipples are manufactured using injection molding (for plastic nipples) and die casting techniques (for aluminum nipples). As will be readily understood by Figure 4 (which shows the molding of a nipple 22), in order to allow removal of the first and second molding segments 42, 44 in the directions indicated by the first and second arrows 46, 468 respectively, it is not possible for the mold segments 42, 44 provide a radius for the inner corner 40.
The aforementioned internal components housed by the rotor housing 4 will now be described in greater detail with particular reference to Figure 8.
First, a top support unit 5 is attached to an internal surface of the rotor housing 4 immediately downstream of the fluid inlet 8. The top support unit 50 comprises caged bearings 52 trapped between an upper steel cover member 54 and a lower bearing seat member 56 of a plastic material. The support unit 50 is manufactured by molding the lower bearing seat member 56 around the upper steel cover member 54 with the caged bearings 52 securely held between them. The arrangement of the top support unit 50 is most clearly shown in Figure 8, although it is also shown in Figures 2 and 9 in the context of the prior art separator 2.
The bearing seat member 56 has a circular shape and a cylindrical wall projecting downwards 58 (enclosing a lower part of the cover member 54) which, in the mounted separator 2, contacts laterally against a cylindrical wall 60 of the rotor housing 4. Contact with the cylindrical wall 60 assists in ensuring correct lateral positioning of the top bearing unit 50 in relation to the rotor housing 4. A second cylindrical wall 62 of the rotor housing 4 is positioned radially into the first cylindrical wall 60, in order to ensure correct axial positioning of the top support unit 50 relative to the rotor housing 4. The top support unit 50 is secured to the rotor housing 4 by means of three threaded fasteners (not shown). The arrangement of the separator 2 is such that the rotating geometric axis of the top support unit 50 is coincident with a common geometric axis 64 of the rotor housing 4.
Three partially circular slits 66 (only two of which are shown in Figure 8 are provided in the top support unit 50 in order to allow an inflow of fluid through them (as shown by arrow 68). The top cover member 54 deflects the inlet fluid of the caged bearings 52, however, as will be understood by those skilled in the art, the underside of the uppermost part of the cap member 54 also deflects (into the caged bearings 52) a mist of lubricating oil that moves upward through a rotor shaft and into the top support unit 50 during use.
The remaining internal components of the separator 2 are mounted separately from the rotor housing 4 and are then located within the housing 4 as a unitary assembly. The unitary assembly comprises a first group of components which, in use of the separator 2, remain stationary in relation to the rotor housing 4 and a second group of components which, in use of the separator 2, rotate about the central geometric axis 64 in relation to both the rotor housing 4 (and the valve unit housing 12) and the first group of components.
The first group of components comprises an annular shaped support plate 70 and a plate shaped member 72, known as a housing insert. The housing insert 72, in combination with the support plate 70, works to separate separate oil from clean gas before the separated oil and clean gas leave the rotor housing 4. The support plate 70 is made of steel and the insertion of housing 72 is made of a plastic material. The support plate 70 and the housing insert 72 are secured to each other by means of three fasteners with screw thread 74 (only one of which is shown in Figure 1 of the accompanying drawings) which threadedly fit into shoulders 76 projecting downwards to from the underside of the housing insert 72. This first group of components will be discussed in more detail later in this description.
The second group of components form a rotor unit and comprise a rotating shaft 78, an upper rotor disc 80, a plurality of individual separating discs 82 which together form a stack 84 of separating discs 82, an end plate 86 and a combined fan and turbine unit. The components of this second group are attached to each other in such a way as to prevent their rotation relative to each other. The second group of components is, however, rotatably fixed to the first group of components by means of a base support unit 90 (see Figure 10 in particular).
The rotor unit formed by the second group of components will now be described in more detail.
The rotating shaft 78 is made of a metallic material and has an annular cross section in order to provide a fluid flow path extending longitudinally 92 over its entire length. In use of separator 2, this flow path 92 allows an oil mist to be transported from a turbine housing upwards through the rotating shaft and into the top support unit 50, in order to lubricate the bearings of said unit 50. A limiting element 93 in the form of an annular disc (with an erect cylindrical wall from its radially outer circumferential edge) is located on an internal shoulder facing upwards of said fluid flow path 92 at an upper end of the rotary axis 78. The restrictor element 93 functions to reduce the flow path area through the rotary axis 78 (thereby providing a nozzle) at an outlet of the rotary axis 78 into the top support unit 50.
The exterior of the rotating shaft 78 is provided with numerous recesses and shoulders for receiving washers that assist in retaining components in the correct axial position on the rotating shaft 78. Such a washer 94 is clearly shown in Figure 6 as providing a shoulder facing up against which a washer 95 contacts. A helical compression spring 96 contacts a shoulder facing upward of washer 95. The circumferential recess in which washer 94 is located is of sufficient width (that is, the dimension of the recess in the axial direction) to allow washer 94 to move axial along rotary axis 78 (within the recess). This allows the spring 96 to apply axial force to the base support unit 90.
Other recesses are provided on the external surfaces of the rotary axis 78 to locate and retain components on said axis 78.
Each of the upper rotor disk 80, separator disks 82 and end plate 86 have a frusto-tapered portion (defining an upper frusto-conical surface 102) with a plurality of wheel spoke members extending radially inward from there to a hub element which, in use, is located around the rotating axis 78.
Although the wheel radius members of the upper rotor disc 80 and separator discs 82 have open spaces between them to allow fluid flow axially through them along the rotary axis 78, the radius members of the end plate 86 are joined together on their lower surfaces, in order to prevent an axial flow of fluid along the rotating axis 78 upwardly beyond the end plate 86 or downwardly beyond the end plate 86.
The frusto-conical geometry of the upper rotor disk 80 and the end plate 86 is substantially identical to that of the separating disks 82, in order to allow the upper rotor disk 80 and the extreme plate 86 to be stacked with the separating disks 82, where the upper rotor disk 80 is located at the top of the separator disk stack 84 and the end plate 86 is located at the base of the separator disk stack 84. Furthermore, although the separator disks 82 are understood by the skilled person to be comparatively completed in order to allow a large number of disks to be provided in a relatively short stack 84, the rotor disk 80 and the end plate 86 are considerably thicker than the separator disks 82 in order to provide rigidity at each end of the disk stack 84 and thereby allow a compressive axial force to be uniformly applied to the frusto-conical parts of the separating discs by the upper disc 80 and end plate 86. The co pressure is generated more specifically by the helical compression spring 96 which presses upwards on the underside of the hub 98 of the end plate 86.
With reference to the compression of the disc stack 84 between the upper disc 80 and the end plate 86, it should be understood by the skilled person that the adjacent separating discs 82 within the stack 84 must remain spaced apart in order to allow a flow of fluid through of separator 2. This spacing of the separating discs 82 is provided by means of a plurality of ribs 100 (known as caulking) provided on the upper surface of the frusto-conical part of each separating disc 82. Each caulking 100 extends from an edge radially inner 104 of said upper surface 102 to a radially outer edge 106 of said surface. The caulks 100 remain proud of said upper surface 102 and, in the assembled pile 84 of the separating discs 82, contact the underside of the adjacent disc above. As understood by a person skilled in the art, each separator disk 82 is located on the rotating axis 78 in one of only six possible angular positions relative to the rotating axis 78, and the positioning of the caulks 100 on said upper surface 1001 is such that caulking of adjacent discs 82 must align with each other when discs 82 are arranged and any of these six positions. As a result, the compressive force applied to the disc stack 84 by the end plate 86 is transmitted through the stack 84 via the aligned caulking 100 without the spacing between adjacent separating discs 82 closing.
With reference also to the compression force applied to the stack of separator disc 84, it should be understood by the skilled person that this force is generated by the helical compression spring 96 and applied to the extreme plate hub 98. Due to the rigidity of the extreme plate 86, the compressive force is transmitted from the hub 98 to the frusto-conical part 108 of the end plate 86 via a plurality of radially extending rays 110 of the end plate 86. The compression force is then transmitted to the disc stack 84 via the frustum part conical 108, and transmitted upwards through stack 84 (via caulking 100) to the frusto-conical part 112 of the upper rotor disc 80. The compressive force is transmitted from the frusto-conical part 112 to the hub 114 of the upper rotor 80 via six radii extending radially
116. The compressive force is transmissible from the frusto-conical part 112 to the hub 114 due to the stiffness of the upper rotor disc 80. An axial movement of the upper rotor disc 80 upwards along the rotary axis 78, in reaction to the force of compression, is avoided by a location of the upper rotor disc hub 114 in a circumferential recess 118 on the outer surface of the rotating shaft 78 (see Figure 6 in particular). Frictional forces between the hub M and the outer surface of the rotating shaft 78 prevent relative rotation between them.
It will be seen by Figures 6 and 8 in particular that the hub 114 of the upper rotor disk 80 extends axially downward along the rotating axis 78 to a point just above the end plate hub 98. More specifically, the hub 114 is extends along the total depth of the separator disk stack 84 and thereby separates the hub 120 from each separator disk 82 from the rotary axis 78 (see Figure 7). The hub 120 of each separator disk 82 has a hexagonal shape defined by a hexagonal opening through which the rotating axis 78 and the upper rotor disk hub 114 extend. The rotational movement of the separating disc hub 120 relative to the upper rotor disc hub 114 (and therefore relative to the rotating axis 78) is prevented by means of six keys 122 which are provided axially along the length of the disc hub. upper rotor 114 and extend radially into six corners of the hexagonal opening defined by the separating disc hub 120. This location of the keys 122 prevents lateral and rotational movement of a separating disc hub 120 relative to the rotating axis 78.
The separating disk hub 120 of each separating disk 82 is connected to the frusto-conical portion 124 of each separating disk 82 by means of twelve radially extending rays 125. The rays 126 (and in reality the rest of the associated separating disk 82) are made of a relatively resiliently flexible plastic material. However, spokes 126 are nevertheless capable of withstanding lateral and rotational forces to which they are subjected without deformation. It will be understood by the skilled person that the compressive force generated by the helical spring 96 is transmitted through the separator disc stack 84 via the caulking 100 instead of the separator disc spokes 126.
It should also be understood by the skilled person that the relative geometry of the keys 122 and hexagonal hub 120 of each separator disk 82 ensures that, as mentioned above, each separator disk 82 is located in the step of receiving image data 78 in one of only six angular positions. However, the polar or angular positions of the caulking 100 of the separating discs 82 are the same regardless of which of the six angular positions is used and, therefore, there is no possibility of the separator disc stack 84 being mounted on the data receiving step. image 78 with the caulking 100 of the separator discs 82 being misaligned.
For the sake of clarity, certain Figures in the accompanying drawings show a disc stack with a small number of separating discs present. With specific regard to the prior art separator 2, Figures 1, 2, 8, 9 and 10 have been simplified in this way.
As shown in Figure 5, a second circumferential recess 128 is provided at an upper end of the rotary axis 78 at a location above the first recess 118. The second recess 128 receives a second helical compression spring 130. The position of the second recess is so that, in the assembled prior art separator 2, the lower end and the second spring 130 are moved away from the hub 114 of the upper rotor disk 80 (see Figure 6) and are prevented from axial downward movement along the rotary axis 78 by a upward facing face formed by the second recess 128. In addition, in the mounted separator 2, the cage of the cage bearings 52 contacts and compresses down the second spring 130 (with the upper end of the rotary shaft 78 remaining away from the cover member 54 top support unit 50 - see Figure 8 in particular). The second spring 130 applies a load to the top support unit 50 and thereby reduces vibrations and associated wear on the top support unit 50.
The fan and turbine unit 88 of the second group of internal components is shown in Figure 6 of the accompanying drawings. Before the fan and turbine unit 88 is mounted on the lower end of the rotating shaft 78, the lower end of the shaft 78 is located through a central circular opening provided in each of the support plate 70 and housing insert 72 of the first group internal components. In doing so, the lower end of the rotary axis 78 is also extended through the base support unit 90, which is secured in the central opening of the support plate 70 (see Figures 8 and 10 in particular).
The combined fan and turbine unit 88 is attached to the lower end of the rotary shaft 78, which projects downwardly from the bottom side of the support plate 70. The fan and turbine unit 88 is retained and positioned on the lower end of the rotary shaft 78 by means of a second washer 132 (retained in a third circumferential recess of the shaft 78) and a second washer 133 contacting an upward facing surface of the second washer 132. The axial positioning of the fan and turbine unit 88 on the shaft rotary 88, as determined by the second washer 132, results in an upper surface unit being pressed in contact with a deflector washer 139 which, in turn, is pressed in contact with the base support unit 90. In the mounted separator 2, the inner groove of the base support unit 90 contacts the first washer 94 and presses this washer 94 upward against the propensity of the first compression spring 96. The pressing the inner groove, baffle washer 139 and fan and turbine unit 88 against the second washer 132 is in order to retain these elements in a fixed rotational position relative to the rotary axis 78.
The rotor unit of the separator 2 is rotated in a direction indicated by arrow 134 (see Figure 1) by means of a hydraulic impulse turbine. The fan and turbine unit 88 comprises a Pelton wheel 136 having a plurality of buckets 138 evenly spaced along its circumference. In use of separator 2, an oil jet is directed from a nozzle (not shown) inside the turbine housing 178 towards the circumference of the Pelton wheel 136. More specifically, the jet is directed along a tangent to a circle passing through the plurality of buckets 138, so that the jet enters a bucket aligned with its surface. The jet flows along said surface following the internal profile of the bucket and is then turned by said profile to flow along another surface and then be ejected from the bucket. The result is that the jet turns the wheel 136.
A fan having a plurality of blades 140 is also integrally formed with the wheel 136. The blades 140 are located on the wheel 136 in close proximity to the underside of the support plate 70. The plurality of fan blades 140 is also in approximately the same axial position along the rotating axis 78 as the base support unit 90. The fan blades 140 extend radially outward from the adjacent base support unit 90. It will be understood by those skilled in the art that the fan blade 140 rotates about the central geometry axis 64 when the turbine wheel 136 is rotated. In doing so, the fan blades 140 effectively flush fluid from the region between the wheel 136 and the underside of the support plate 70, thereby reducing the pressure of the fluid in the region of the base support 90 and pulling oil apart from one location above the support plate 70 down through the base support unit and into the turbine housing 178 under the support plate 70.
For ease of manufacture, wheel 136 is made of upper and lower parts 142, 144 and pressed in contact with each other on line 146 as shown in Figure 8 of the accompanying drawings.
With respect to the first group of internal components, the support plate 70 is made of steel and has a circular shape with a diameter substantially equal to the diameter of the rotor housing 4. The relative geometries are such as to allow the support plate 70 locate on a ledge facing down 148 at a lower end of the rotor housing 4. In this way, the lower open end of the rotor housing 4 is closed by the support plate 70. The support plate 70 is also provided with a central circular opening which, in the mounted separator 2, is concentric with the rotor housing 4. In other words, in the mounted separator 2, the central circular opening of the support plate 70 is centered on the central geometric axis 64 of the rotor housing 4 In addition, as will be particularly evident from Figure 1 of the accompanying drawings, the base support unit 90 is received in the central opening of the support plate 70. The radial portion The outermost part of the base support unit is fixed in relation to the support plate 70. The radially innermost part of the base support unit 90 is located adjacent to the rotary axis 78, but is not fixed to it.
As mentioned above, the first group of internal components also comprises a housing insert 72 which is fixedly attached to the support plate 70. The housing insert 72 works to separate the clean gas from the oil that has been separated from it and to provide an outlet 150 for clean gas, which connects to the outlet opening 10 of the rotor housing 4 (see Figure 1 in particular). The housing insert 72 is provided as a unitary molding of plastic material. However, when describing the housing insert 72 below, the insert will be considered to comprise four parts: an outer cylindrical wall / flap part 152; a trench part 154; a frusto-conical part 156; and an outlet part 158 defining said insertion outlet 150.
The cylindrical flap part 152 of the housing insert 71 has an outermost outer diameter that is substantially equal to the diameter of an inner wall part of the rotor housing 4 with which the flap part 152 contacts. A circumferential recess 159 (see Figure 2) is provided on the outer surface of the flap part 152 to receive an O-ring seal 160, which, in the mounted separator 2, ensures a fluid seal between the housing insert 72 and the housing rotating 4.
The lower end of the cylindrical skirt part 152 contacts the upper side of the support plate 70 and is provided with a circumferential recess 162 (see Figure 12) to receive a second O-ring seal 164. It will be understood that the second ring seal The 164 ensures a fluid seal between the housing insert 72 and the support plate 70.
A second cylindrical wall positioned radially internally to the outer flap part 152 and arranged concentrically with it is connected at its lower end to the flap part 152 to form the ditch part 154. The ditch part 154, together with the outer flap part 152, forms an annular ditch (or gutter) 166 running along the inner cylindrical wall of the rotor housing 4. Ditch 166 has a U-shaped cross section and, when using separator 2, collects separate oil droplets , which are hurled from the separating discs 82 and run downwards inside the rotor housing 4 under the action of gravity (and under the action of a downward spiraling gas flow, as is mentioned in more detail here). Ditch part 154 is provided with four drainage holes 168 (see Figure 11 in particular), through which oil collected in ditch 166 can flow in order to pass into a region enclosed by a lower side of the housing insert 72 and an upper side of the support plate 70 when using the separator 2.
The third part 156 of the housing insert 72 has a frusto-conical shape and is suspended by the trench part 154. The fustproof cone 156 is provided with a central circular opening which, on the mounted separator 2, has a central geometric axis coinciding with the central geometric axis 64 of the rotor housing 4. An elongated recess 170 (see Figure 11) is provided on the upper surface of the frusto-conical part 156. This recess 170 defines a fluid path for clean gas that joins with the part outlet 158 of the housing insert 72. The flow path provided by the recess 170 begins at its upstream end with a descending step 172 from the upper surface of the frusto-conical part 156. The side walls 174, 176 of the recess 170 increase by height in the downstream direction when the fluid path progresses outward from the center of the housing insert 72. As will be evident from the top view of the housing insert 72 provided by Figu 11, recess 170 provides a straight fluid path, having a length approximately equal to half the diameter of the housing insert 72.
The outlet parts 158 of the housing insert 72 is provided in the form of a generally cylindrical tube, which extends through the ditch 166 between the openings of the outer flap part 152 and the ditch part 154.
A view of the separator 2 attached to a turbine housing 178 is shown in Figure 2. Separator 2 is attached to the turbine housing 178 by means of three threaded fasteners 180, each of which passes through one of the three integral integrals with the lower end of the rotor housing 4. Only a fastener 180 and boss 182 are shown in the cross-sectional side view of Figure 2. It will be understood by Figure 2 by those skilled in the art that the support plate 70 (and therefore all components of the first and second groups) is retained in the required position relative to the rotor housing 4 by virtue of the turbine housing 178 pressing the support plate 70 for contact with the shoulder facing down 148, when the rotor housing 4 and the turbine housing 178 are fixed together. The support plate 70 is essentially secured between the rotor housing 4 and the turbine housing 178 by means of the threaded fasteners 180. When the threaded fasteners 180 are tightened and the support plate 70 is brought into contact with the shoulder 148 as a result , the second helical compression spring 130 is compressed by the top support unit 50.
In operation of the separator 2, a nozzle (not shown) in the turbine housing 178 directs a jet of oil over the turbine wheel 136 in order to rotate the turbine wheel in the direction indicated by arrow 134, as previously described in relation to Figure 1. This rotation of the turbine wheel drives the rotation of the rotor unit as a whole, in the direction of arrow 134 about the central geometry axis 64 of the rotor housing 4. In other words, the rotating axis 78; the upper rotor disc 80, the stack 84 of the separator discs 82; the end plate 86; and the combined fan and turbine unit 88 (i.e. collectively referred to herein as the rotor unit) rotate together as a unitary unit within the rotating housing with respect to said housing 4 and the support plate 70; inserting housing 72; and the turbine housing 178.
The vented gas from the engine crankcase and requiring treatment by the separator 2, is introduced into the separator 2 via the fluid inlet 8 located at the top of the rotor housing 4. As indicated by arrow 68 in Figure 8, the inlet gas enters the rotor housing 4 in a parallel direction with and in line with the central geometry axis 64 and flows through three slots 66 n the top support unit 50 before flowing beyond the six spokes 116 of the upper rotor disk 80. The rotational movement of the six spokes also results in a lateral movement of the fluid located between said spokes by the fact that said fluid moves tangentially from the circular path of the spokes 116 and is effectively thrown out towards the cylindrical wall of the rotor housing 4. In essence , the six spokes 116 give a cylindrical movement over the inlet gas.
When the incoming gas flows downward through rays 116, 126 of the upper rotor disc 80 and the separating discs 82, the gas is moved laterally towards the cylindrical wall of the rotor housing 4 via the spaces between the adjacent separating discs 82 , as shown by the arrows 184 in Figure 8. The caulking 100, together with the frictional forces applied by the separating discs 82, give a lateral movement in the fluid located in the disc stack 84, which results in said fluid moving outwards in towards the cylindrical wall of the rotor housing 4. This movement of the fluid, caused by the rotation of the disc stack 84 is a primary mechanism by which fluid is pulled into the separator 2.
It will be understood by those skilled in the art that oil droplets 186 tend to gather together and form larger droplets on the perimeter of the disc pile 84. In this relationship, capillary forces acting on smaller oil droplets (due to the small spacing between the adjacent separating discs 82) tend to prevent small droplets from being thrown from the disc stack 84. However, when more oil is moved through a separating disc, the smaller droplets gather together at the perimeter and form larger droplets having sufficient mass (and associated “centrifugal” force) to overcome capillary force. The oil is then thrown over the cylindrical wall of the rotor housing 4. Once received by said cylindrical wall, the oil droplets 186 tend to run downwards under the action of gravity, and the gas flow through the separator 2 inwards. annular ditch 166. The outermost circumferential edge of the separator stack 84 is sufficiently spaced into the cylindrical wall of the rotor housing 4 to allow oil droplets to flow unimpeded by the separating discs 82 down into said valley 166. O-ring sealing 160 ensures that oil droplets seep into ditch 166, instead of between housing inserts 72 and rotor housing 4 with the possible consequence of contaminating clean gas flowing through outlet 150 of the housing insert 72 (as will be more readily understood with reference to Figure 1).
The oil droplets 186 gathering in the ditch 166 are drained from there through the four drainage holes 168. The drainage action is assisted by fluid pressure gradients within the rotor housing 4 and turbine housing 178. More specifically, it will be understood by those skilled in the art that, due to the rotational movement of the rotor unit, the fluid pressure within the rotor housing 4 is greater at the peripheral edge of the separator disc stack 84 than in the region between the underside of the insertion of housing 72 and the upper side of the support plate 70. As a result, there tends to be a flow of clean gas down through the drain holes 168. This fluid flow tends to push separate oil droplets along the annular ditch 166 and down through the drain holes 168 on the support plate 70 below. This flow of gas fluid is indicated by arrow 188 (see Figure 8 in particular). The flow of gas fluid moves radially inward across the upper surface of the support plate 70 towards the central circular opening of the housing insert
72. This flow through the support plate 70 tends to push separate oil droplets through the support plate 70 towards the base support unit 90, through which said oil droplets pass. The rotating fan blades 140 of the combined fan and turbine units 88 tend to decrease the static pressure in the turbine housing 178 in the region of the base support unit 90. This in turn helps to draw oil droplets through the base support 90. However, the main means by which the oil droplets are pulled through the base support unit 90 is provided by the deflector washer 139 which, in use, rotates with the turbine unit in relation to the support plate 70 and pumps oil from the rotor housing 4, even if the pressure inside the turbine housing is greater than that inside the rotor housing. The fan blades 140 then hurl said droplets out into the turbine housing 178 from where they can be returned to the engine crankcase. In the meantime, the gaseous fluid seeping through the support plate 70 is pulled upward through the central opening of the insert housing 72 and leaves the rotor housing 4 via the housing insertion skirt 150 and the rotor housing outlet 10 .
It will also be noted with reference to the accompanying drawings that, as well as flowing through the drain holes 168, part of the clean gas flows to the outlet 150, 10 via an alternative route between the extreme plate 86 and the upper part of the ditch part 154 ( without draining into the ditch 166). This alternative route is indicated by arrow 190.
We have observed that the flow of oil through the base support unit 90 has a beneficial lubricating effect on the support unit. The top support unit 50 is similarly lubricated by an oil mist that naturally occurs in the turbine housing 178 and is transported upward to the top support unit 50 through the longitudinal flow path 92 extending through the rotary axis 78.
Although the prior art separator 2 has proven to operate effectively, there are numerous problems associated with the separator that have been treated with improvement found in the modified separators described below. These problems can be considered in three broad categories.
First, the fluid paths through the separator 2 give rise to pressure losses that adversely affect the flow capacity of the separator and, consequently, the size of the motor with which the separator can be used. A first category of problem associated with the prior art ALFDEX ™ separator can therefore be considered to be related to pressure losses in the fluid flow paths.
Second, the prior art separator arrangement is such that, under certain conditions, clean gas can become contaminated before leaving the separator. Thus, a second category of problem associated with the prior art separator can be considered to be related to an undesirable oil contamination of the clean gas.
Third, certain manufacturing techniques and construction details associated with the prior art separator can result in assembly difficulties and the reliability problem. As such, a third category of problem associated with the prior art separator can be considered to relate to the manufacture and reliability of the separator.
Each of these categories will now be discussed in more detail.
With reference to the fluid flow paths through the separator 2, there are numerous locations where comparatively high pressure losses are experienced. Firstly, the inner corner 40 of the curve of the entry / exit nipples 22, 28 is so pronounced in order to generate a fluid separation from the inner surface of the nipple in the region immediately downstream of said inner corner 40. This separation manifests itself as flow of recirculating fluid (or eddies), which in turn results in energy / pressure losses. However, as described above in relation to Figure 4 of the accompanying drawings, providing a large radius in the inner corner is problematic when manufacturing the inlet / outlet nipple with injection molding or die casting techniques. As a result, the prior art separator 2 experiences pressure losses at the nipples both at the fluid inlet to the rotor housing 4 and at the outlet of the valve unit housing 12. The six spokes 116 of the upper rotor disk 80 have also been identified. as another cause of undesirable pressure losses. Specifically, it will be seen by Figures 5 and 6 in particular that each of the spokes has a rectangular cross section that has a pronounced upper rear edge for an incoming axial flow of the vented gas when the upper rotor disk 80 is rotating in the direction of the arrow 134 (see Figure 5). The shape of the spokes 116 and in particular the pronounced rear edge 192 of each spoke have been found to give rise to fluid separation and undesirable pressure losses.
It has also been found that the particular configuration of the housing insert 72 gives rise to undesirable pressure losses. Specifically, when using separator 2, clean gas seeps down over the frusto-conical part 156 of the housing insert 72 with a rotary movement around the central geometric axis 64 as indicated by arrow 194 in Figure 12. This gas flow clean water flows over the frustoconical part 156 after having flowed down in a spiraling pattern along the inner surface of the cylindrical side wall of the rotor housing 4. It will therefore be understood that the clean gas enters the region between the frustoconical part 156 and the extreme plate above 86 at all points along the circumferential perimeter of the housing insert 72 (instead of entering this region in a particular location). The flow path through the frustoconical part 156, therefore, has a spiraling pattern that can give rise to undesirable pressure / energy losses. In addition, step 172 and the walls 174, 176 of the recess 170 provided in the frusto-conical part 156 generate more areas of fluid separation and associated undesirable pressure losses.
With respect to the second category of the oil contamination problem, numerous details of the prior art separator 2 have been identified that increase the likelihood of clean air becoming contaminated under certain conditions. First, as previously mentioned, the flow of clean gas down through the rotor housing 4 partially enters ditch 166 and tends to pull separate oil droplets through drain holes 168. If the rate of clean air flow is insufficiently high for the particular level of oil contamination being treated, then the oil droplets gathering in the ditch 166 can rise the ditch part 154 of the housing insert 72 and then flow over the frusto-conical part 156 of the housing insert 71 ( see Figure 10). Once oil droplets penetrate the region between the frusto-conical part 156 and the end plate 86, the oil droplets inevitably leave separator 2 contaminating the clean gas. The rise in droplet oil droplets 166 may be a result of a low flow rate of clean gas, which allows an undesirably high amount of oil to collect in ditch 166. The presence of clean gas circulating upward into ditch 166 it may also tend to pull oil droplets up and over the frusto-conical part 156 of the housing insert 72. However, a significant detail of the prior art separator 2 that allows oil droplets to rise upwards out of the ditch 166 is the tubular outlet part 158 (see Figure 12). Although the drainage holes 168 are located on each side of the outlet part 158, it will be seen by Figure 12 of the accompanying drawings that the oil droplets inside the ditch 166 follow a circular path along the base of the ditch 166 and whether the droplets of oil does not flow through drain hole 168 immediately upstream of outlet part 158, then the oil droplets will tend to follow the path indicated by arrow 196 (see Figure 12) and flow upward over outlet part 158 and over frusto-conical part 156 of the housing insert 72.
It has also been found that the separated oil droplets can flow upwards through the central opening of the housing insert 72 and over the frusto-conical part 156 and thereby contaminate the clean gas. This undesirable separate oil flow tends to occur when the rate of clean gas flow through the drain holes 168 and up through the central opening of the housing insert 72 (as indicated by arrow 188 in Figure 8) is relatively high. It will be understood by those skilled in the art that the high flow rate of clean gas results in separate oil droplets being transported upwards through the central opening of the housing insert 72, instead of allowing the separated oil droplets to be pulled down through the base support unit 90 by gravity and the deflection washer 139.
It was also found that excessive oil can be introduced into the separator disc stack 84 via the longitudinal flow path 92 through the rotating shaft 78, as indicated by the arrow 198 shown in Figure 2. During common operating conditions, the oil jet triggering the turbine wheel 136 impacts said wheel and generates a mist of fine oil droplets. This oil mist is carried upwards to the top support unit 50 and then down through the stack of separating discs 82. Ordinarily, the amount of oil transported in this way is sufficient to lubricate the top support unit 50 while being subsequently easily separated from the incoming gas flow by the separator disc stack 84. However, in certain circumstances, the amount of oil transported through the rotating shaft 78 may be so large as to result in oil leaking from the ditch 166 or otherwise flow into the frusto-conical part 156 of the housing insert 72 and subsequently into the clean gas outlet 10. This can occur when, for example, the separator 2 is tilted and the lower end of the rotary shaft 78 is directly exposed to the surface of a reservoir of oil kept inside the turbine housing 178.
With reference to the third category of the problem related to difficulties with manufacturing and reliability, the following problems were identified with the separator of the prior art 2.
First, with respect to the manufacture of separator 2, it has been found that the use of threaded fasteners 32 to secure an inlet / outlet nipple to the rotor housing 4 and valve unit housing 12 can be time consuming and requires an O-ring seal 36.
The length of time it takes to manufacture the prior art separator 2 is also affected by the need for the top support unit 50 to be axially aligned with the base support unit 90 such that both support units 50, 90 are rotating about the same geometry axis 64. Specifically, the rotor housing 4 is made of a plastic material by means of an injection molding process and the inventors have found that there is a tendency for the rotor housing 4 to warp during cooling. As a result of this warping, the position of the first cylindrical wall 60 of the rotor housing 4 (which is laterally located in the top support unit 50) tends to be located in a different lateral position in relation to the lower end of the rotor housing 4 of which it was intended. As a result, the support plate 70 (and thus the base support unit 90) can be laterally displaced from its intended position. This problem can be mitigated by allowing the rotor housing 4 to cool for a comparatively long period following the injection molding process. This long cooling period reduces the warping of the rotor housing 4 but increases the manufacturing time.
Another problem associated with the separator unit 2 concerns the interface between various components, such as that between the rotor housing 4 and the valve unit housing 2. More specifically, if the separator 2 is to be provided with a different valve unit 14 from the one originally intended (or in reality without a valve unit), then a different rotor housing 4 must also be used in order to ensure the correct interface with the new valve unit (or other pipe system where no valve units are to be used). This can unduly increase costs and assembly times. Furthermore, the asymmetry of the rotor housing 4 (caused by the molding profile provided in said housing 4 to interface with the valve unit housing 12) tends to result in a warping of said housing 4 during manufacture and this in turn results in problems during assembly (for example, problems related to component misalignment).
It has also been identified that the large O-ring seal 160 provided in the housing insert 72 may fail. More specifically, O-ring sealing is required to seal against two large joining diameter surfaces, one surface being provided at the housing insert 72 and one surface being provided over the cylindrical wall of the rotor housing 4. Both the housing of rotor 4 as well as housing insert 72 have relatively large manufacturing tolerances, which can result in O-ring sealing 160 not properly sealing the two components. In addition, since the two components are manufactured from a plastic material employing injection molding techniques, each molding (and particularly the molding of the rotor housing 4) is subject to warping following the injection molding process. This may also result in the O-ring sealing 160 failing to properly seal the two components 4, 72. It will be understood that if the O-ring sealing 160 fails, then separate oil will leak into the region 200 between the flap part outer cylindrical 152 of the housing insert 72 and the cylindrical wall of the rotor housing 4. The oil leaking into this region 200 will finally pass into outlet 150 of the housing insert 72 and will contaminate the clean gas. If the O-ring seal 160 fails at the outlet 150 location, then separate oil will tend to leak beyond the O-ring seal 160 and directly enter the outlet 150. This sealing problem can increase manufacturing time when: (i ) action is taken to reduce the warping effect (increasing the cooling time following the injection molding process) or (ii) the leak components are replaced after testing the product.
In addition, a molding burr located in the recess 159 receiving the O-ring seal 160 may result in the failure of the O-ring seal.
A reliability problem associated with the arrangement for locating the separating discs 82 in a fixed angular orientation relative to the rotating axis 78 has also been identified. As explained above in relation to Figure 7 of the accompanying drawings, the separating discs 82 are prevented from rotating with respect to to the rotating shaft 78 by means of six keys (attached to the rotating shaft 78) fitting with a hexagonal opening in the hub 120 or each separating disk 82. However, the vibrations to which a separator is typically exposed during use (such as motor vibrations) can cause wear of the interface between the keys 122 and the hexagonal opening in the hub 120. This wear can result in significant relative rotary movement between the separating discs 82 and the rotating axes 78. In fact, it has been found that the adjacent separating discs 82 rotate in relation to each other to such an extent that the caulks 100 become misaligned, allowing the space between the adjacent separating discs 82 close. If this occurs with a significant number of discs 82, then the depth of the separating disc stack 84 can be reduced to such an extent that hub 98 of end plate 86 is pressed by compression spring 96 against upper rotor disc hub 114 It will be understood that the end plate 86 is then no longer capable of imparting a compressive force to the stack of separating disc 84 and, as a result, individual separating discs 82 will be free to move axially up and down along the axis rotary 78 (as well as rotating with respect to rotary axis 78). This movement is highly undesirable and significantly reduces the separation performance of the separator disc stack 84.
Another identified reliability problem concerns seizing corrosion at the interfaces between (i) the rotating shaft 78 and the top / bottom support units 50, 90; and the rotary axis 78 and the first compression spring 96. It should be understood by those skilled in the art that grip corrosion occurs when relative movement between components is possible (for example, due to the relatively loose fit between said components). The rotary axis 78 extends through the top and bottom support units 50, 90 and the first compression spring 96 with a relatively loose fit. This allows an axial preload to be applied to the top and bottom support units 50, 90 by the first and second compression springs 96, 130. Specifically, it will be understood by the drawings that the first compression spring 96 applies an axial force to the base support unit 90 and the second compression spring 130 apply axial force to the top support unit 130. The loose fit of the rotary shaft 78 with the top / base support units 50, 90 and the first compression spring 96 allows vibratory movements between components.
This, in turn, gives rise to corrosion by seizing on said components. The relative movements between the components can also allow the entry of hard particles between said components, which can further accelerate wear and result in reliability problems.
The improved separators developed to address the above problems will now be described with reference to Figures 13 to 41.
Those skilled in the art will immediately understand by the accompanying drawings that the developed improved separators have many components that are similar or identical to the prior art separator 2 in terms of the function they perform and their general configuration. Such components will be described below in the context of the improved separators using the same reference numerals that were used above in relation to the separator of the prior art 2. For example, with reference to Figure 13 of the accompanying drawings, a skilled person will understand that the The improved separator 2 'shown in this Figure comprises a generally cylindrical rotor housing 4', which corresponds to the rotor housing 4 of the prior art separator 2 and performs a similar function. Structural and functional differences between such corresponding components will be evident to the skilled person by the accompanying drawings, however these, in general, will be discussed in detail when the differences are of significance in the treatment of co-problems and providing improvements over the separator of the prior art 2 or the manufacturing process of the prior art separator 2.
It will be understood by those skilled in the art that the improved separator 2 'comprises a generally cylindrically shaped rotor housing 4' and numerous internal components which function to separate ventilated gas oil directed into said rotor housing 4 '. As described below, some of the internal components are located inside the 4 'rotor housing, while other internal components (for example, a combined fan and turbine unit) are located outside the 4' rotor housing, but are however located in another housing (for example, a turbine housing).
An upper end of the cylindrical housing 4 'is provided with an upright annular shoulder 6', which defines a fluid inlet 8 'for the improved separator 2'. The gas ventilated by a crankcase and requiring oil removal from it, enters the separator 2 'via the fluid inlet 8'.
An opening 10 'of a cylindrical wall 201 of the rotor housing 4' provides an outlet through which clean gas passes from the interior of the rotor housing 4 'into a separate housing 12' of a valve unit 14 '(see Figures 13,14el5 in particular). The outlet opening 10 'extends through, and is therefore surrounded by, a cylindrical boss 202, which extends from the outer surface of the rotor housing 4'.
The valve unit 14 'comprises a valve arrangement for controlling the flow of clean gas from the separator 2'. As for the above description of the prior art separator 2, detail of the operation of the valve unit 14 'will not be described here. A skilled person, however, will be familiar with the functional operation of a valve unit for use with the improved separator.
As will be evident from Figures 13 and 14 and in particular from Figure 15, the internal components of the valve unit 14 'are entirely closed in a housing 12' which is distinct from the rotor housing 4 '. More specifically, the valve unit housing 12 'comprises first and second parts 203, 205, which join together to form a sealed enclosure in which the internal components of the valve unit 14' are arranged. With reference to Figure 15, it will be seen that an upper end of the first part 203 of the valve unit housing 12 'is provided with a boss 207 through which a conventional screw thread fixation 16' extends for fitting by screw thread. screw with another boss 209 on the rotor housing 4 '.
It will also be seen from Figure 15 that a lower end of the first part 203 the valve unit housing 12 'is provided with a generally cylindrical part 211, which extends away from the valve unit housing 12' and into the interior of the rotor housing 4 'via outlet opening 10' of rotor housing 4 '. An O-ring seal 213 is located on an external surface of the cylindrical part 211 and contacts against a shoulder (defined on said surface) that faces the interior of the rotor housing 4 'of the mounted separator 2'. The shoulder thereby prevents undesirable movement of the O-ring seal 213 along the cylindrical part 211 when said part 211 is pushed through the outlet opening 10 'during assembly and the O-ring seal 213 fits with said opening 10' . More specifically, the O-ring seal 213 seals in contact with the internal cylindrical surface of the boss 202 surrounding the outlet opening 10 '.
Although the O-ring seal 213 is provided towards the root end of the cylindrical part 211 (i.e., the end of the cylindrical part adjacent to the rest of the valve unit housing), a second O-ring seal 215 is provided on the outer surface of a free end of the cylindrical part 211 (distal to the root end). As in the case of the first O-ring seal, the second O-ring seal contacts a shoulder facing the interior of the rotor housing 4 ', in order to avoid undesirable movement of the second O-ring seal 215 as it seals is pressed into an end-use position of the mounted separator 2 '. More specifically, it will be understood by Figure 15 that, in the mounted separator 2 ', the second O-ring seal 215 sealingly fits with the outlet 150' of a housing insert 72 '.
It will also be understood by the skilled person that the first O-ring seal 213 prevents clean gas and / or oil droplets from leaking between the rotor housing 4 'and the valve unit housing 12' and thereby undesirable leakage from the separator 2 'into the environment. It will be further understood by the skilled person that the second O-ring seal 215 prevents oil droplets from leaking into outlet 150 'of housing insert 72' and thereby contaminating the clean gas leaving the rotor housing 4 'via the cylindrical part 211.0 small outside diameter of the cylindrical part 211 and the first and second O-ring seals 213, 215 (compared to the large-diameter O-ring seal 160 of the prior art separator 2) allows use comparatively small manufacturing tolerances, which ensures a low failure rate with respect to the two O-ring seals 213, 215. In this relation, we observe, for example, that the extent of the warping in the relatively small diameter cylindrical part 211 will be smaller than in the relatively large diameter rotor housing 4 of the prior art separator 2.
The lower end of the first part 203 of the valve unit housing 12 'is provided with a second boss 207 located on one side of the cylindrical part 211. As in the case of the first boss 207 provided on the upper end of the first part 203, the second boss 207 at the lower end of the first part 203 receives a conventional screw thread fixation 16 'for screw thread fitting with a second boss 209 provided at a lower end of the rotor housing 4' (see Figure 18 with respect to said second bosses 207, 209).
As a consequence of the valve unit housing 12 'being a separate housing from the rotor housing 4' and being geometrically independent of it (other than for the union of the cylindrical part 211 with the outlet opening 10 'and the interface formation of the upper pairs and lower projections 207, 209), the rotor housing 4 'of the improved separator 2' has a total shape that approximates that of a cylinder more rigorously than the rotor housing 4 of the prior art separator 2. In this relation , it is noted that the prior art rotor housing 4 comprises a relatively complex and bulky molding profile on one side which serves to form part of the prior art valve unit housing 12 (instead of merely a joining interface with him). However, with reference to Figure 15, it will be seen that the rotor housing 4 'of the improved separator 2' does not comprise the complex and bulky molding profile mentioned above.
As a consequence of the rotor housing 4 'having a shape approaching that of the cylinder, housing 4' can be manufactured using injection molding techniques with a reduced degree of warping during the cooling process, compared to the housing 4 of the prior art separator 2. This allows for easier axial alignment of the top and bottom support units 50 ', 90'. In addition, we observe that the rotor housing 4 'shown in the accompanying drawings can be coupled with the valve units alternative to the valve unit 14' shown in the accompanying drawings provided that the alternative units and valve have a cylindrical part 211 suitable for union with the outlet opening 10 'of the rotor housing 4' and lugs 207 suitable for joining with the lugs 109 of the rotor housing 4 '(as in the case of the valve unit housing 12' shown in Figure 15). For example, if an alternative valve unit has a housing with a cylindrical part and two shoulders identical to the cylindrical part 211 and shoulders 207 shown in Figure 15 and with the same relative positioning as shown in Figure 15, then the alternative housing can be considerably larger than the valve unit housing 12 'shown in Figure 15 and housing an internal valve arrangement entirely different from that of the valve unit 14' shown in the accompanying drawings. This allows for a modular construction of a separator 2 'with an increased commonality of parts between different separator arrangements.
With reference to Figure 15, it will be seen that the housing 12 'of the valve unit 14 is provided with an upright annular shoulder 18' that defines a fluid outlet through which the clean gas passes from the separator 2 '. The annular shoulder 18 'provided on the valve unit housing 12' is substantially identical to the annular shoulder 6 'provided on the rotor housing 4'. Due to their similarity, the input and output lugs 6, 18 can interchangeably receive input / output nipples having the same interface profile. Identical inlet / outlet nipples 22 ', having a 90 ° curvature, are shown in Figure 13. The inlet nipple 22' is shown, in cross section, joined with the 6 'shoulder of the rotor housing 4' and is further shown separate from said shoulder 6 'of Figure 17.
As will be most clearly seen from the side cross-sectional view of Figure 16, the inner surface 216 of nipple 22 'combines with a curved surface of the shoulder 6' to define a fluid flow path having a 90 ° curvature and significantly with a radius in the outer and inner corners. As a result, the tendency for the fluid to separate from the inner corner of the curvature is greatly reduced compared to the flow of fluid through the pronounced corner 40 of the prior art arrangement. In turn, pressure losses are also reduced. The interface between the input / output nipples 22 'and the respective housing shoulders 6', 18 'will now be written in more detail with reference to the rotor housing shoulder 6' (which is identical to the shoulder 18 'of the housing unit valve 12 ').
As shown in Figures 16 and 17, the upright shoulder 6 'of the rotor housing 4' is provided as an annular boss having a generally cylindrical wall 217 centered on a longitudinal geometric axis coinciding with a central geometric axis 64 'of the rotor housing 4 '.
A free end of the cylindrical wall 217 (distal to the rest of the rotor housing 4 ') is provided with a circumferential edge 219 forming a curved surface 221 extending into an opening formed by the shoulder 6'. In cross section (see Figure 16), the curved surface 221 has a partially circular shape and extends through an arc 223 of approximately 110 °. The partially circular surface 221 is oriented so that a radial 225 of said surface 221 extends parallel to the longitudinal geometric axis of the cylindrical wall 217. In the particular arrangement shown in Figure 16, the arc 223, through which the partially circular surface 221 sweeps, ends at the aforementioned radial 225. It will also be understood by the lateral cross-sectional view of Figure 16 that an external cylindrical surface 227 of the shoulder 6 'is coincident with said radial 225 and intersects with the partially circular surface 221 to form an upper edge 229 of the 6 'shoulder.
Repeating, with reference to Figure 16 in particular, that nipple 22 'will be understood to be provided with a profile to join with the shoulder 6', so that the inner surface 216 of nipple 22 'matches the partially circular surface 221 of the boss 6 'to provide a smooth surface without ridges, bosses facing up / down, discontinuities and / or any other details that generate pressure losses. More specifically, the geometry of the nipple 22 'is such that the transition from the inner surface 216 of the nipple 22' to the partially circular surface 221 of the shoulder 6 'does not show a fluid flow over the combined surface (in either direction through nipple 22 ') with an obstruction or other pressure loss generating detail. Given the symmetry of the shoulder 6 ', this remains the case regardless of the angular or polar positioning of the nipple 22' in relation to the housing 4 '.
The smooth transition between the inner surface of the nipple 22 'and the partial circular surface 221 is achieved in the improved separator arrangement 2' by configuring the inner surface of the nipple 22 ', so that, at each point where the inner nipple surface 216 meets the partially circular surface 221, the inner nipple surface 216 is oriented at a tangent to the partially circular surface 221. Therefore, with respect to the inner corner of the curvature formed by the nipple / shoulder combination, the inner nipple surface 216 meets the partially circular surface 221 at the aforementioned edge 229 of the shoulder 6 'and, at this meeting point, is oriented perpendicularly to the aforementioned radial 225 (i.e., tangentially to the partially circular surface 221). The point at which the inner nipple surface 216 meets the partially circular surface 221 of the shoulder 6 'moves progressively radially inward through the partially circular surface 221 as it progresses circumferentially around the shoulder 6' to the outer corner of the curvature formed by nipple / cam combination. The inner nipple surface 216 can be seen in Figure 16 meeting the partially circular surface 221 at an edge 231 of the inner nipple surface 216.
In practice, due to the limitations of injection molding techniques and the cost constraints associated with high tolerances, the transition between the partially circular surface 221 and the inner nipple surface 216 will not necessarily be entirely free from discontinuities or other loss-generating details. pressure. In particular, there may be a gap between the edge 231 of the nipple 22 'and the partially circular surface 221 of the shoulder 6'. This span can be reduced in practice by manufacturing one or both of the nipple 22 'and partially circular surface 221 of steel (or other metallic material) with die casting techniques.
The nipple 22 'is further provided with a generally cylindrical shoulder in the form of a cylindrical wall 233 having internal and external diameters equal to that of the cylindrical wall 217 of the housing shoulder 6'. The cylindrical wall 233 of the nipple 22 'joins concentrically with the cylindrical wall 217 of the housing shoulder 6' when the nipple 22 'is located on said shoulder 6'. A curved wall 235 extends radially outwardly from the aforementioned inner nipple surface edge 231 to an upper edge of the cylindrical nipple wall 233. In cross section, curved wall 235 is partially circular in shape and configured to be concentric with, and contacting, the partially circular surface 22 'of the housing shoulder 6'.
Two ribs are located on the outside of the nipple 22 'and extend from the curved wall 235 in order to provide said wall 235 with additional stiffness and to prevent or reduce a flexion of the nipple 22' between said wall 235 and the rest of the nipple 22 ' (see Figure 13).
As in the prior art separator 2, the nipple 22 'of the improved separator 2' is manufactured using conventional injection molding or die casting techniques with the consequence that a pronounced inner corner 239 is formed (see Figure 34). This corner 239 can be considered analogous to the inner corner 40 of the prior art nipple
22. However, it should be understood that the presence of the partially circular surface 221 of the housing shoulder 6 'in combination with the improved nipple 22' ensures that a radius is provided for the inner part of the curvature of the flow path in the housing 4 '. As mentioned above, this is independent of the angular orientation of the nipple 22 'in relation to the housing 4'. The separation of fluid from the inner surface of the curvature is thereby reduced or avoided and pressure losses in this part of the path and flow are similarly reduced or avoided.
Finally, with respect to the geometry of the nipple 22 ', a second end of said nipple (distal to the end provided with the housing interface profile) is provided with teeth or saws 38' on its outer surface to grasp a hose which, in use, is located on the second end of the nipple.
It is again emphasized that the rotating housing shoulder 6 'is identical to the shoulder 18' on the valve unit housing 12 'and that an outlet nipple 22' is connected to this second housing shoulder 18 'in the same manner as described above in relation to the 6 'rotor housing shoulder.
It should be understood from the above that the nipple 22 'can be rotated unimpeded while positioned on and in contact with the boss 6' as shown in Figure 16. As such, the nipple 22 'can be welded rotated on the boss 6' in order to fix it attach nipple 22 'to the housing in a required angular orientation. It will be noted by those skilled in the art that this method of securing nipple 22 'does not require the use of threaded fasteners as in the separator of the prior art 2. It should also be understood that this rotation welding technique allows nipple 22' to be attached in any angular orientation in relation to the 4 'housing and provides a full circumferential (or closed loop) seal without the need for an O-ring seal. Specifically, the heat produced by frictional forces acting between the contact surfaces of the housing 4 '(i.e., the shoulder 6') and the nipple 22 'during the relative rotation of said surfaces results in the melting of said surfaces. The rotation is then stopped and said surfaces solidify, thereby joining together.
Although the above rotation welding is an effective method of joining the material of the nipple 22 'to that of the housing 4'; other methods of joining said materials can be used (for example, adhesive bonding, ultrasonic welding or vibration welding).
The above-mentioned internal components will now be described in greater detail with particular reference to Figure 34.
First, a top support unit 50 'is attached to an internal surface of the rotor housing 4' immediately downstream of the fluid inlet 8 '. The top support unit 5 'is identical to the top support unit 50 of the prior art separator 2 and, as such, comprises cage bearings 52' trapped between an upper steel cover member 54 'and a lower bearing seat member 56 'of a plastic material. The top support unit 50 '(and also a base support unit 90') comprise rod bearings (as in the prior art separator 2), but may alternatively comprise sliding or friction bearings.
More specifically, the bearing seat member 56 'has a circular shape and a cylindrical wall projecting downwards 58' (enclosing a lower part of the cap member 54 ') which, in the mounted separator 2', is located inside (however without contacting laterally against) a cylindrical wall 60 'of the rotor housing 4'. The cylindrical wall 60 'extends downwardly from an upper inner surface of the rotor housing 4'. A circular ridge 238 also extends downwardly from an upper inner surface of the rotor housing 4 'and is positioned radially into the first cylindrical wall 60'. The cylindrical wall 60 ', circular crest 238 and the aforementioned shoulder 6' of the rotor housing 4 'are positioned concentric with each other and are centered on the central geometric axis of the rotor housing 4'.
As will be described in greater detail below (with reference to Figures 37 to 41), the top support unit 50 'is secured to the upper inner surface of the rotor housing 4' by means of a rotation welding technique. Specifically, the lower bearing seat member 56 'is welded to the ridge 238. Threaded fasteners are not used to secure the top support unit 50' to the rotor housing 4 ', as in the prior art separator 2. The arrangement is so that the rotary axis of the top support unit 50 'is coincident with the central axis 64' of the rotor housing 4 '.
Three partially circular slits 66 '(only two of which are shown in Figure 34) are provided in the top support unit 50' in order to allow a flow of inlet fluid to pass through them (as shown by the arrows 68 '). The upper cover member 54 'deflects the inlet fluid from the caged bearings 52'. As in the prior art separator 2, the lower side of the uppermost part of the cap member 54 'also deflects (into the caged bearings 52') a mist of lubricating oil that moves upwards through a rotor shaft during use.
The remaining internal components of the separator 2 'are mounted separately from the rotor housing 4' and are then removably located, in part, within the housing 4 'as a unitary assembly. As for the separator of the prior art 2, this unitary assembly can be considered as comprising a first group of components which, in use, rotate and take a central geometric axis 64 'in relation to both the rotor housing 4' (and the unitary housing valve ') and the first group of components.
The first group of components comprises an annular shaped support plate 70 'and a plate shaped housing member / insert 72'. As in the prior art separator 2, the housing insert 72 'and the support plate 70 work in combination to separate separate oil from clean gas before the separated oil and clean gas leaves the rotor housing 4'. The support plate 70 'is made of steel and the housing insert 72' is made of a plastic material. The support plate 70 'and the housing insert 72' are secured together by means of three fasteners with screw thread 74 '(see Figure 19) that threadedly fit into the shoulders 76' projecting downwards from one side bottom of the housing insert 72 '. The support plate 70 'closes the open end of the rotor housing 4' to provide an enclosed internal space of the housing 4 'in which several of the second group of components are located. In this connection, the rotor housing 4 'can be considered as a first housing part defining an internal space to receive components to separate substances (for example, oil and gas) and direct the separate substances to different exits of said internal space. The support plate 70 'can be considered as a second housing part defining said internal space with the first housing part.
The first group of components will be discussed in more detail later in this description.
The second group of components form a rotor unit and comprises a rotating shaft 78 ', an upper rotor disc 80', a plurality of individual separating discs 82 'which together form a stack 84' of separating discs 82 ', a disc of fan 140, an end member / plate 86 ', a splash guard disc 242 and a combined fan and turbine unit 88'. The rotating shaft 78 'is made of a metallic material, while the rest of the aforementioned components of the second group are made of plastic and manufactured using injection molding techniques. The aforementioned components of the second group are attached to each other in such a way as to prevent or at least limit their rotation relative to each other. Helical compression springs (of a metallic material) are also provided in the second group of components, as will be described in more detail below. The second group of components is rotatably mounted in the first group of components by means of a base support unit 90 'and, in the mounted separator 2', it is rotatably mounted in the rotor housing 4 'by means of the top support unit 50 '.
The rotor unit formed by the second group of components will now be described in more detail.
The rotary axis 78 'has an annular cross section in order to provide a fluid flow path extending longitudinally 92' over its entire length. In use of the separator 2 ', this path and flow 92' allows an oil mist to be transported from a turbine housing upward through the rotating shaft and into the top support unit 50 'in order to lubricate the bearings of said unit 50 '. The exterior of the rotary axis 78 'is provided with numerous recesses and shoulders which assist in retaining components in the correct axial position of the rotary axis 78'.
Each of the upper rotor disc 80 ', separating discs 82', fan disc 240 and extreme plate 86 'has a frusto-conical part (defining upper and lower frusto-conical surfaces) connected to a central hub element that, in use, is located around the rotating axis 78 '.
In the case of the upper rotor disc 80 ', separating discs 82' and end plate 86 ', the frusto-conical part is connected with the central hub element associated with a plurality of radius members extending radially inward from there. These spoke members have open spaces between them to allow fluid flow axially through them along the rotating axis 78 '.
In the case of fan disk 240, the frusto-conical part 290 is connected to the associated central hub element 292 by means of a second frusto-conical part 294. This second frusto-conical part 294 is continuous in order to provide a barrier for the fluid and thereby prevent an axial flow of fluid along the rotary axis 78 ', upwardly beyond the fan disk 240 or downwardly beyond the fan disk 240.
The frusto-conical shape of the second frusto-conical part 294 has an even greater angle than that of the other frusto-conical parts of the improved 2 'separator. In other words, the opposite sides of the second frusto-conical part 294 diverge / converge more quickly than in the case of the first frusto-conical part 290 of the fan disk 240 or the frusto-conical parts of the upper rotor disk 80 ', disks separators 82 'and end plate 86' (and, in reality, the frusto-conical shaped segregating ceiling member 268 of the housing insert 72 ') all have the same included angle. The central hub element 292 is a vertical cylindrical wall from the second frusto-conical part 294 (see Figures 26 and 33 in particular). Longitudinally extending slots 296 (only one of which is shown in Figure 26) are provided through the entire thickness of the cylindrical wall of the fan hub element 92 to receive a key 254 extending radially from the rotating shaft 78 '. In this way, rotation of the fan disk 240 with respect to the rotary axis 78 'is prevented.
The underside of the first frusto-conical part 290 of the fan disk 240 is provided with a plurality of caulking members 298 spaced equidistant from the central geometric axis of the fan disk 240. Each caulking member 298 is provided as a straight ridge projecting downwards from the bottom side of the first frustoconical part 290 and extending in a radial direction from a radially outer edge of the first frusto-conical part 290. In the mounted separator 2, the caulking members 298 contact the surface upper part of the frustoconical part of the extreme plate 86 'and thus ensure a spacing between the fan disk 240 and the extreme plate 86' through which the fluid can pass (as indicated by the arrow 188 'in Figure 34). During use of the separator 2 ', the rotation of the caulking members 298 provides a rotary movement in the fluid between the fan disk 240 and the end plate 86'. As a consequence, said fluid is moved out towards the cylindrical wall 201 of the rotor housing 4 'and it flows (or falls) down onto the support plate 70'. The gaseous fluid ejected from the space between the fan disk
240 and the end plate 86 'also flows down onto the support plate 70' or directly leaves the rotor housing 4 'as will be explained in more detail below.
With respect to the end plate 86 ', a radially innermost circular edge of the frusto-conical part 108' is connected to a central hub element 98 'through a plurality of radius members 110' (see Figure 18). However, a cylindrically shaped wall 300 also extends downwardly from said radially innermost edge of the frusto-conical part 108 '. In the mounted separator 2 ', the cylindrical wall 300 is centered on the central geometry axis 64' and extends sufficiently downward along the rotary axis 78 'to extend through the central opening provided in the insert housing 72'. Although said wall 300 has a generally cylindrical shape, the inner surface 302 of said wall 300 defines a frusto-tapered shape so that the internal diameter of the cylindrical wall 300 is reduced in an upward direction in the mounted separator 2 '. The outer cylindrical surface of the wall 300 has a diameter substantially the same as the central opening of the housing insert 72 'and, in the mounted spacer 2', is located in said opening with minimum spacing between the wall 300 and the housing of the 72 '. This tight fit, while allowing relative rotation between the extreme plate 86 'and the insertion housing 72', helps to reduce the amount of separated oil that can flow between said wall 300 and the central opening of the insertion housing 72 ', in order to contaminating clean gas. In addition, the internal frusto-conical surface 302 of said wall 300 functions to resist the passage of oil droplets flowing upwards into the space between the fan disk 240 and the end plate 86 '. It should be understood by those skilled in the art that the oil droplets contacting the frusto-conical surface of wall 300 will be subjected to a rotating motion and, due to the frusto-conical shape of said surface, to a force acting downwards.
The splash guard disk 242 includes a planar annular disk 304 which is connected, by means of six radius members 306 extending radially inward from there, to a central hub element 308 which, in the mounted separator 2 ', is located around the rotating axis 78 '(see Figure 28 in particular). The diameter of the central opening defined by the planar annular disk 304 is substantially equal to the inner diameter of the lower end of the cylindrical wall 300 of the end plate 86 '. A flow of fluid passing through the splash guard disk 242 into the region between the fan disk 240 and the end plate 86 'is therefore not presented with a significant pressure loss generating detail at the junction between the protection disk of splash 242 and the end plate 86 '. It will be understood that the annular disk 304 provides a flange member extending radially from the lower end of said cylindrical wall 300 and, in use, works to cover any spacing between the outer surface of said cylindrical wall 300 and that part of the housing insert 72 ' defining the central opening through which said wall 300 extends. In this way, the planar annular disk 304 reduces the likelihood of separate oil droplets splashing or otherwise moving upward from the support plate 70 'and through the central opening of the insert housing 72' in order to contaminate clean gas.
It should also be noted that said region between the fan disk 240 and the end plate 86 'defines a flow path 616 for fluid to pass through an inlet 618 (defined by the splash guard disk 242) to an outlet 620 (defined by radially external perimeter edges of the fan disk 240 and the end plate 86 '), as shown in Figure 34.
The hub element 308 of the splash guard disc 242 is provided as a cylinder with its upper end closed with a flat wall disposed perpendicular to the longitudinal axis of said cylinder (and, in the spacer mounted 2 ', to the central axis 64 '). The inner diameter of said cylinder is greater than the outer diameter of the rotating axis 78 'and the planar wall is provided with a central opening through which said axis 78' passes through the mounted separator 2 '. The arrangement is such that, in the mounted separator 2 ', the rotating axis 78' and the cylinder of the hub element 308 define an annular space between them, which receives a helical compression spring 96 'to press the splash protection disc 242 against contact with the end plate 86 ', which in turn compresses the fan disk 240 and the disk stack 84' against the upper rotor disk 80 '.
It will be understood by those skilled in the art that the splash guard disc 242 is manufactured separately from the end plate 86 'in order to allow the cylindrical wall 300 of the end plate 86' to be located through the central opening as the insert housing 72 ' . This would not be possible if the splash guard disk 242 was integral with the end plate 86 'because the outer diameter of the annular disk 304 is greater than the diameter of the central opening in the housing insert 72'.
As alluded to above, the frusto-conical geometry of the upper rotor disc 80 ', fan disc 240 (with respect to its first frusto-conical part) and the end plate 86' is substantially identical to that of the separating discs 82 '. This allows the upper rotor disk 80 ', fan disk 240 and end plate 86' to be stacked with the separator disks 82 ', where the upper rotor disk 80' is located on top of the pile of separator disk 84 'and the end plate 86 'is located at the base of the separator disc stack 84'. The fan disk 240 is located between the end plate 86 'and the separator disk 86' at the bottom (i.e. at the bottom) of the separator disk stack 84 '.
In addition, while the separating discs 82 'will be understood by the skilled person to be comparatively thin in order to allow a large number of discs to be provided in a relatively short stack 84', the upper rotor disc 80 'and the end plate 86 are considerably thicker than the separating discs 82 ', in order to provide stiffness at one end or the other of the disc stack 84' and thereby allow a compressive axial force to be uniformly applied to the frusto-conical parts of the separating discs 82 ' by means of the upper disk 80 'and the extreme plate 86'. It should be understood that the compressive force is generated by said helical compression spring 96 ', which presses upwards on the underside of a hub 308 of the splash guard disk 242. In turn, the hub 308 of the protection shield disk splash 242 presses upwards on the bottom side of the contact hub 98 'of the end plate 86'.
With reference to the compression of the disc stack 84 'between the upper disc 80' and the end plate 86 ', it will be understood by the skilled person that, as in separator 2 of the prior art, the separating discs 82' adjacent within the stack 84 'must remain spaced apart to allow fluid flow through the improved 2 'separator. This spacing of the separating discs 82 'is provided in the improved separator 2' by means of a plurality of spacers 246. Each spacer 246 is a small point located on, and remaining proud of, the upper surface 102 'of the frusto-conical part 124' of each separator disk 82 '(see Figure 20).
The separator disk 82 'further down the stack 84' can optionally also be moved away from the fan disk 240 to allow fluid flow between them. If such spacing is necessary, then suitable spacers are used. Ideally, the upper surface of the first frusto-conical part of the fan disk 240 (which is located under the frusto-conical parts of the disc stack 84 'and is connected to the fan disc hub via the second frusto-conical part of the fan disk 240) is provided with spacers 246 in the same way as the frusto-conical part of each separator disk 82 '.
Each of said spacers 246 has a circular shape, although other shapes can be used (for example, an oval shape can be used). Any alternative shapes for the frusto-conical part 246 spacers have curved edges in order to reduce fluid pressure losses in the fluid flowing beyond the spacers.
A first group of spacers 246 is arranged in a concentric circle with and adjacent to an inner circular edge 104 'of said upper surface 102'. Each spacer 246 of this first group is located adjacent to that part of the inner circular edge 104 'where a radius of the disc 82' joins with the frusto-conical part of the disc 82 '. A second group of spacers 246 is arranged in a concentric circle with and adjacent to an outer circular edge 106 'of said upper surface 102'. A third group of spacers 246 is arranged in a concentric circle with and approximately halfway between the inner and outer circular edges 104 ’, 106’ of the frusto-conical part of the disc 82 ’.
As will be explained in more detail below, each separator disk 82 '(and, in fact, fan disk 240) is located on the rotary axis 78' in one of many possible angular positions relative to the rotary axis 78 ', and the positioning of the spacers 246 on said upper surface 102 'is so that the spacers 246 of the adjacent discs 82' must align with each other when the discs 82 'are arranged in any of these three positions. In other words, when the separating discs 82 'are pushed axially over the rotary axis 78' and in contact with each other to form the aforementioned stack 84 ', it is inevitable that (i) each spacer 246 of a particular disc 82' located directly above a spacer 246 of an adjacent disk 82 'located under said particular disk 82' of stack 84 ', and that (ii) each spacer 246 of a particular disk 82' is located directly below spacer 246 of an adjacent disk 82 'located above said particular disk 82' of stack 84 '. As a result, the compressive force applied to the disc stack 84 'by the end plate 86' is transmitted through the stack 84 'through the aligned spacers 246 without the spacing between adjacent separating discs 82 closing. This ensures that the fluid remains able to flow between the separating discs 82 '.
It will be seen from the drawings that the spacers 246 have a small radial dimension, as well as a small circumferential dimension, relative to the size (diameter) of the associated separating discs. This allows the fluid to flow relatively unimpeded by the spacers in a circumferential direction through said upper disk surface 102 ', as well as in a radial direction through said surface 102'. This ensures that fluid flow pressure losses between adjacent discs 82 'are minimized.
The upper rotor disc 80 'and the rotary axis 78' are shown in isolation from the other components of the separator 2 'of Figures 21 and 23 of the accompanying drawings. A hub 114 'of the upper rotor disc 80' is molded on the outer surface of the rotary axis 78 'and is thereby connected to said axis 78'. This connection prevents relative rotation between the hub 114 'and the rotary axis 78'.
The hub 114 'of the upper rotor disc 80' extends axially upward along the rotary axis 78 'and terminates at the upper end of said axis 78'. The upper part of the rotary axis 78 ', around which a second helical compression spring 130' is located, is provided with a coating (a sleeve) of a plastic material (preferably a thermoplastic material). This coating protects the spring 130 'and, in particular, the shaft 78', from seizing corrosion. The first and second groups of internal components of an alternative embodiment for the first embodiment 2 'are shown in Figure 19. The alternative separator is the same as the first embodiment other than because the uppermost part of the rotary axis 78 'is absent from the plastic liner adjacent to the second coil spring 130'.
The hub 114 'of the upper rotor disc 80' also extends axially downward along the rotary axis 78 'and ends at a point just above the base support unit 90'. The base support unit 90 'thereby contacts a metal end of the rotary axis 78' of the mounted separator 2 '. More specifically, hub 114 'extends along the entire depth of the separator disc stack 84' and thereby separates hub 120 'from each separator disc 82' from the rotary axis 78 '. It will also be understood that hub 114 'also provides rotary axis 78' with a coating (a sleeve) of a plastic material (preferably a thermoplastic material) in the region of the first helical compression spring 96 '. Again, this coating protects the spring 96, and in particular the shaft 78 ', from seizing corrosion.
The frusto-conical portion 112 'of the upper rotor disc 80' is connected to the hub 114 'by twelve radius members extending radially 116'. Each member of radius 116 'has a rectangular shaped cross section, an upper (smaller) side 310 to which the edge radially innermost 312 of said frusto-conical part 112' is joined. Each radio member 116 'extends axially downwards from said edge 312. This arrangement is such that, when the upper rotating discs 80' rotate during the use of the separator 2 ', each member radius 116' functions as a blade fan and allows movement over the adjacent fluid. As will be understood by those skilled in the art, the movement granted over the fluid by each radius member 116 'results in the fluid draining tangentially from the circular path of the radius members 116' and being effectively hurled out under the frusto-conical part 112 'and through the disc stack 84 'and towards the cylindrical wall of the rotor housing 4'. The operation of the radius members 116 'as fan blades results in the rotation of the upper rotor disc 80' pulling gas into the rotor housing 4 ', through the fluid inlet 8' (as indicated by the arrow 68 'of Figure 34 ) and through the spaces 600 between the radius members 116 ', whereby said spaces 600 represent an entrance to the rotor unit.
The fluid entering the rotor housing 4 'passes through three partially circular slits 66' of the top support unit 50 '. The radius members 116 'of the upper rotor disc 80' are located immediately below the three partially circular slits 66 'of the mounted separator 2'. With particular reference to Figure 34 of the accompanying drawings, it will be seen that the radial dimensions of the partially circular slots 66 'is less than the radial dimension (i.e., length) of the radius members 116' with the result that a large proportion of the incoming fluid initially impacts only that extension of radius member 116 'located directly below partially circular slits 66'. This length of each radius element 116 'is provided with a curved fluid guide vane 314 extending upwardly from its upper side (or leading edge) 310. The purpose of each guide vane 314 is to reduce or eliminate the pressure losses associated with a separation of the inlet fluid from the spoke members 116 '. This is achieved by presenting the substantially axial flow of the input fluid within the rotor housing 4 'with a guide vane having an aerodynamically shaped cross section and a bead oriented to have a substantially zero angle of attack with the incoming fluid flow (or other angle of attack that does not result in a separation of the fluid from the guide reed 314).
A cross-sectional view through the length of a radius member 116 'provided with a guide vane 314 is shown in Figure 22. The surface of the guide vane 314 works to guide the fluid, which is approaching the edge of attack 310 of radius element 116 ', for alignment with radius element 116'. A cord 316 associated with the leading edge 318 of the guide vane 314 is oriented to have substantially zero angle of attack with the fluid flowing over said guide vane 314. The direction of this fluid in relation to the guide vane 314 is indicated by the arrow 320 and, as indicated in Figure 22, it will be understood to be a function of the axial velocity of (i) inlet fluid flow (Q / A, where Q is the rate of volumetric fluid flow through the inlet; and A is the area cross-section of the inlet flow path) and (ii) the tangential speed of the guide vane 314 (or where ω is the angular speed of the upper rotor disk; er is the radial distance of the guide vane from the center of rotation ). Since the direction 320 of the fluid flow relative to the guide vane 314 depends on the radial position r along a guide vane 314, the cord 316 can be oriented at an angle that varies with the radial position. In other words, the fluid guide vane 314 can be provided with a twist to ensure correct alignment of the guide vane 314 with the incoming fluid flow at all radial positions along the guide vane 314. More specifically , the acute angle 322 between the bead 316 and the vertical reference line 324 (parallel to the central geometric axis 64 'of the mounted separator 2') can progressively increase from a more inner radial position and towards a more outer radial position along of a member 116 'radius.
It will be understood by the skilled person that, when using the improved separator 2 ', the incoming air flows axially downward through the three partially circular slits 6' and impacts on the guide vanes 314, which are located a short distance below said slits 66 'and which rotate in a circular path around the central geometric axis 64'. Since the cord 316 of the leading edge 318 of each guide vane 314 is oriented to have a substantially zero angle of attack for the incoming fluid flow, said fluid flows over both the low pressure side 324 and the high side pressure 326 of the guide vane 314 and is guided to flow in an axial direction relative to the radius members 116 'without separating from the guide vane 314 or associated radius member 116'. Pressure losses incurred by the fluid flowing through the upper rotor disc 80 'are thereby avoided or minimized.
A further consequence of the reduction in pressure losses provided by the guide vanes 314 is that the number of radius members 116 'can be increased (compared to the prior art separator 2) without undesirably affecting the rate of fluid flow through the separator 2 'as a whole. The increased number of radius members 116 'allows greater compressive forces to be transmitted between the frusto-conical part 112' and the hub 114 'of the upper rotor disc 80'. The increased number of radius members 116 'can also improve the balance of the upper rotor disc 80'.
It should be noted that Figure 22 represents a schematic cross-sectional view of a guide vane 314 and associated radius member 116 'and is not necessarily representative of a particularly preferred geometry or in reality of particularly preferred rotational speeds and fluid flow rates .
Referring to Figure 21, a cylindrical rim 328 will be seen provided concentrically with, and erect from, the radially innermost edge 312 of the frusto-conical part 112 '. In the mounted separator 2 ', the rim 328 is located radially outwardly from the cylindrical wall projecting downward 58' from the top support unit 50 '. The rim 328, however, is located in close proximity to said cylindrical wall 58 'in order to prevent (or significantly restrict) a leakage of fluid between them (see Figure 34 in particular).
Three keys 254 extend radially from hub 114 'of the upper rotor disk 80' as will be more readily seen by Figure 13 of the accompanying drawings. The three keys 254 are spaced equidistant from the central longitudinal axis of the upper rotor disk 80 'and extend axially along the hub 114' (and, consequently, along the rotary axis 78 ') on a lower side 330 from the members radius 116 'to a point along the hub 114' which, in the mounted separator 2 ', is located approximately halfway along the central hub element 292 of the fan disk 240.
Each key 254 has a root part 350 and a tip part 352. The root part 350 joins with the rest of the hub 114 '. The tip part 352 connects with the root part 350 and provides a free end for key 254. The root part 350 of each key 254 is wider (i.e., has a larger circumferential dimension) than the part tip 352. As a result of the different widths of the root and tip parts 350, 352, a step 354 is provided on each side of each key 254 at the junction between the root and tip parts 350, 352. With reference to Figure 23 in particular, it will be seen that the width of the root part 350 of each key 254 increases from a lower end of each key 254 to an upper end of each key 254. In addition, the width of each root part 350 is approximately equal to width (i.e., the circumferential dimension) of one of the twelve spokes 116 'of the upper rotor disk 80'. The tip portion 352 of each key 254 is also circumferentially aligned with a radius member 116 'and joined therewith.
The hub 120 'of each separator disk 82' has an opening 252 through which the rotating axis 78 'and the upper rotor disk hub 114' extend (see Figures 23, 24 and 25 in particular). The rotational movement of the separating disc hub 120 'relative to the upper rotor disc hub 114' (and therefore relative to the rotating axis 78 ') is prevented by means of three keys 254 which are provided axially along the length of the hub. upper rotor disk 114 'and extending radially into a corresponding female joining profile defined by opening 252 of separator disk hub 120'. This location of the keys 254 prevents lateral and rotational movement of a separating disc hub 120 'relative to the rotary axis 78'. More specifically, the surfaces 356 of the tip portion 352 of each key 254 (whose surfaces 356 extend generically radially) contact the corresponding surfaces 358 (surfaces these 358 also extending generically radially) of said joining profile to prevent relative rotation a separator disk 82 'and the upper rotor disk hub 114' (and rotary axis 78 '). We observe that the contact surfaces 356, 358 press against each other, in use, in a direction generally perpendicular to each of said surfaces 356, 358 and, for this reason, there is little or no relative sliding movement of said surfaces 356, 358 and little or no frictional wear associated with said surfaces 356, 358 that may result in an increased or undesirable relative rotation between a separating disk 82 'and the upper rotating disk hub 114'.
The separating disc hub 120 'of each separating disc 82' is connected to the frusto-conical portion 124 'of each separating disc 82' by means of twelve radially extending members 126 '. As in the prior art 2 'separator, spokes 126' (and the rest of the associated separating disc 82 ') are made of a relatively thin and resiliently flexible plastic material. Repeating, as in the separator of the prior art 2 ', the spokes 126' are able to resist the lateral and rotational forces to which they are subjected without deformation and the compression force generated by the helical spring 96 'is transmitted through the stack of separating disc 84 'saw the spacers 246 instead of the spacer disc rays 126.
It will also be understood by the skilled person that the relative geometry of the keys 252 and the opening 252 of each separator disk 82 ’
100 ensures that, as mentioned above, each separator disk 82 'is locatable on the rotary axis 78' in one of only three angular positions. Due to the positioning of the spacers 246 in relation to the opening 252, the polar or angular positioning of the spacers 246 of the separating discs 82 'remains the same, in relation to the rotating axis 78', regardless of which of the three angular positions is used and, Accordingly, there is no possibility of the separator disc stack 84 being mounted on the rotary axis 78 '. However, each separator disc 82 'is provided with a marker that can be aligned with the markers of other discs 82' in the disc stack 84 '. In this way, all disks 82 'within the stack 84' will have the same angular position relative to the rotary axis 78 '. The marker is provided as a rib 256 located on the hub between the two spokes 126 'and extending a short distance radially outward.
For the sake of clarity, Figures 13. 15, 19, 30, 27, 33, 34 of the accompanying drawings show a disc stack 84 'with a reduced number of separating discs present.
An annular recess 258 (see Figure 21), concentric with the rotary axis 78 ', is provided on an upper surface of the upper rotor disk hub 211'. The annular recess 258 receives a second helical compression spring 130 'and prevents downward axial movement of this spring 130' along the rotary axis 78 '. In addition, in the mounted separator 2 ', the cage of the caged bearings 52' contacts and compresses the second spring 130 '(with the upper end of the rotary shaft 78' remaining away from the cover member 54 'of the top support unit) 50 '- see Figure 34 in particular).
During the assembly of the improved separator 2 ', all except the combined fan and turbine unit 88' of the second group of internal components are interconnected with each other. The upper rotor hub 114 '(and the rest of the upper rotor disc 80') is injection molded with the
101 rotary axis 78 ’in situ. The stack 84 'of the separating discs 82' is then slid axially along the rotating axis 78 'of its lower end, in order to locate in contact with the lower side of the frusto-conical part 112' of the upper rotor disc 80 ' .
Before the fan and turbine unit 88 is mounted on the lower end of the rotating shaft 78, the lower end of the eighth 78 is located through a central circular opening provided in each of the support plate 70 and housing insert 72 of the first group internal components. In doing so, the lower end of the rotary axis 78 is also extended through the base support unit 90, which is attached to the central opening of the support plate 70 (see Figures 8 and 10 in particular).
With regard also to the compression force applied to the stack of separating disc 84 ', it should be understood by the skilled person that this force is generated by the helical compression spring 96'. During use of the separator 2 ', the compression spring 96' rotates with the rotating axis 78 'and a lower end of the compression spring 96' contacts a radially internal groove of the base support unit 90 'in order to press against it and transfer said force upwards to the splash protection hub 308. The compression force is then transmitted from the splash protection hub 308 to the extreme plate hub 98 '. A rotation of the splash guard 242 with respect to for example 86 'is resisted due to frictional forces between the splash guard hub 308 and the extreme plate hub 98' (which will be understood to be a function of the compressive force).
Due to the rigidity of the end plate 86 ', the compression force is transmitted from the hub 98' to the frusto-conical part 108 'of the end plate 86' via said plurality of radially extending members 110 '. The compression force is then transmitted to the caulking members 298 of the fan disk 240 via the frusto-conical part 108 ’, and then transmitted from the frusto-conical part 190 of the fan disc 240 upward through the
102 stack 84 '(via spacers 246) to the frusto-conical part 112' of the upper rotor disc 80 '. The compressive force is transmitted from the frusto-conical part 112 'to the hub 114' of the upper rotor disc 80 'via twelve radially extending 116' radii. The compression force is transmissible from the frusto-conical part 112 'to the hub 114' due to the stiffness of the upper rotor disc 80 '. Axial movement of the upper rotor disc 80 'upwards along the rotary axis 78', in reaction to the compressive force, is prevented by a location of the upper rotor disc hub 114 'in contact with a shoulder facing down 250 on the rotary axis 78 '. An axial movement of the upper rotor disc 80 'down along the rotary axis 78' is prevented by a location of the upper rotor disc hub 114 'in contact with an annular shoulder facing upwards 248 of the rotary axis 78'.
Adjacent disks 82 'of the disk stack 84' can optionally be fixedly attached to each other. This will tend to increase the stiffness of the disc stack 84 'and ensure that the relative rotational positions of the adjacent discs 84' do not change (ie, ensure that the disc spacers 246 remain aligned in order to transmit compressive force without the space between adjacent discs 82 'closing). Discs 82 'can be joined together by welding (for example, ultrasonic welding).
As in the prior art separator 2 ', before the fan and turbine unit 88' is attached to the lower end of the rotary shaft 78 ', the lower end of the shaft 78' is located through a central circular opening provided in each of the support plate 70 'and housing insert 72' of the first group of internal components. The lower end of the rotary axis 78 'is also extended through the base support unit 90', which is attached to the central opening of the support plate 70 '(see Figures 29 and 30 in particular).
The combined fan and turbine unit 88 ’is attached to the lower end of the rotating shaft 78’, which projects downward from
103 on the underside of the support plate 70 ’. The fan and turbine unit 88 'is retained in position on the lower end of the rotary shaft 78' by means of a washer 132 '(retained in a circumferential recess at the lower end of the rotary shaft 78') and a helical compression spring 360 located around the lower end of the rotating shaft 78 'and contacting a face-up surface of washer 132'.
Washer 132 'and compression spring 360 are located within a cavity of the combined fan and turbine unit 88'. The compression spring 360 presses upward within said cavity, in order to propel the fan and turbine unit 88 upwardly in contact with a radially internal groove of the base support unit 90 '. This arrangement is most clearly evident from Figure 30 of the accompanying drawings. With reference to this Figure, it will be understood that a deflecting surface facing upwards 139 'is provided in said unit 88' and is located radially internally to the fan blades 140 'of said unit 88'. The baffle surface 139 ’performs the same function as the baffle washer 139 of the prior art separator 2, but is provided integrally with the fan and turbine unit 88’ instead of as a separate contacting component. A radially internal portion of the deflector surface 139 'is pressed upwards in contact with an internal support groove of the base support unit 90' which, in turn, is pressed upwards against the support plate 70 '. The baffle surface 139 'and the radially external support groove of the base support unit 90' are axially spaced apart to allow separate oil flow downwardly through the base support unit 90 'and radially outwardly through of said axial spacing into the turbine housing.
The rotor unit of the separator 2 is rotated in a direction indicated by the arrow 134 '(see Figures 29 and 30) by means of a hydraulic impulse turbine. As in the prior art 2 'separator, the
104 fan and turbine 88 'comprises a Pelton wheel 136' having a plurality of buckets 138 'evenly spaced along its circumference. In use of the separator 2 ’, an oil jet is directed from a nozzle (not shown) inside the turbine housing towards the circumference of the Pelton 136’ wheel. More specifically, the jet is directed along a tangent to a circle passing through the plurality of buckets 138 ', so that the jet enters a bucket aligned with its surface. The jet flows along said surface following the internal profile of the bucket and is then turned by said profile to flow along another surface and then ejected from the bucket. The result is that the jet turns the wheel 136 ’.
A fan having a plurality of blades 140 'is also integrally formed with the wheel 136'. The paddles 140 'are located on the wheel 136' in close proximity to the underside of the support plate 70 '. The plurality of fan blades 140 'are also in approximately the same axial position along the rotary axis 78' as the deflector surface 139 'and the base support unit 90'. The fan blades 140 'extend radially outwardly from the adjacent base support unit 90'. It will be understood by those skilled in the art that the fan blades 140 'rotate around the central geometric axis 64' that the turbine wheel 136 'is rotated. In doing so, fan blades 140 'effectively flush fluid from the region between the wheel 136' and the underside of the support plate 70 ', thereby reducing the fluid pressure in the region of the base support unit 90' and assisting in pulling oil separately from a location above the support plate 70 'down through the base support unit and into the turbine housing under the support plate 70'.
For ease of manufacture, wheel 136 ’is made in upper and lower parts 142’, 144 ’and pressed and contacted with each other on line 146’ by two screw threaded fasteners (only one of which is shown in
105
Figure 30 of the accompanying drawings).
The plurality of fan blades 140 'and the deflector surface 139' are integrally formed with the upper part 142 'of the fan and turbine unit 88'. The lower part 144 'of the fan and turbine unit 88' is provided with a lower plate member 364 which, on the mounted separator 2 ', is located in a plane perpendicular to the central geometric axis 64' and through the opening of a downward hole for the flow path 92 'of the rotary axis 78'. The plate member 364 is however moved away from said opening to the flow path 92 ', in order to allow a flow of fluid into said opening.
The plate member 364 is provided with four openings 366 which, on the mounted separator 2 ', are located equidistant along an imaginary circle centered on the central geometric axis 64'. It should be understood by a skilled person that an alternative number of openings 366 can be used, although the openings must be arranged in order to ensure a rotating balance of the 88 'fan and turbine unit.
Significantly, the openings 366 are located radially outwardly from the opening to the flow path 92 '. It should be understood, therefore, that the arrangement is such that a mist of oil droplets can flow upwards through the openings 366 of the turbine housing and thereby enter the cavity within the fan and turbine unit 88 'and flow upward through the flow path 92 'of the rotary axis 78'. However, it should also be noted that the flow from the openings 366 to said opening of the flow path 92 is in a radially inward direction. When using separator 2 ', the fan and turbine unit 88' is naturally rotating in the direction indicated by arrow 134 'and, although a mist of oil droplets can flow radially inward from the openings 366 into the flow path 92 ', comparatively larger bodies of oil seeping through the openings 366 will be moved in one direction
106 lateral by the rotating plate member 364 and will tend to be thrown outwardly away from the opening for flow path 92 '. For example, in the event that a vehicle tilts or otherwise moves in such a way to splash oil upwards from the turbine housing through openings 366, to flood the fan / turbine cavity 88 ', the lateral movement granted in the oil within said cavity tends to prevent said oil from flowing inwards towards the rotary axis 78 '. An undesirable flow of large amounts of oil upward through the rotating shaft 78 'and into the disk stack 84' is therefore prevented.
Two drainage openings 368 are provided in the plate member 364 in order to allow oil to drain from the cavity within the fan and turbine unit 88 'back into the turbine housing. The drainage openings 368 are located diametrically opposite each other and form a slit in the plate member 364 and in a generally cylindrical wall rising from the circular perimeter of said plate member 364. The location of the drainage openings 368 in a radially outermost part from the turbine cavity ensures that the oil flung to the outer perimeter of said cavity along the rotating shaft 78 'effectively drains from the fan and turbine unit 88'.
Although the plate member 364 is shown in the embodiment of Figures 29 and 30 as being integral with the bottom part 144 'of the fan and turbine unit 88', in an alternative embodiment shown in Figures 31 and 32 of the accompanying drawings end plate 364 is provided as a circular disc separate from bottom 144 of fan and turbine unit 88 '. Referring to Figures 31 and 32, it will be seen that the separate plate member 364 of the alternative embodiment is a circular disc provided with openings 366 in the same manner as in Figures 29 and 30. However, the alternative plate member 364 is secured in position relative to the rest of the 88 'fan and turbine unit by the
107 screw threaded fasteners 362 (extending through it) and is absent from the drain openings 368. In this alternative arrangement, the drain openings 368 are provided only in the cylindrical bottom wall 144 ', which is arranged concentrically with the circular perimetric edge of the plate member 364 and extends upwards from it. The bottom part 144 'of the fan and turbine unit 88' is further provided with a second cylindrical wall 370, which is located inside the cavity of the fan unit and turbine 88 'and extends downwards to provide a downward facing annular surface against which the plate member 364 can be pressed by the two screw threaded fasteners 362. Recesses are provided on the downward facing annular surface in order to provide a fluid path 372 between said cylindrical wall 370 and the plate member 364. In use, the oil seeping out through the upper surface of the plate member 364 passes for drain openings 368 via flow path 372.
Although the fan and turbine unit 88 'of Figures 31 and 32 is provided with an external cylindrical wall and a plate member 364 which together define a cavity and additionally also provided with another cylindrical wall 370 against which the plate member 364 is located, the fan and turbine unit 88 is in other respects similar to that of the prior art separator 2 and is attached to the rotary shaft 78 'in the same way as in the prior art separator 2. Specifically, the fan and turbine unit 88 'is attached to the rotary axis 78' by means of a washer 133 ', which presses upwards on the lower part 144' of said unit 88 'and is held in position by means of a washer 132, located in a circumferential recess in the surface rotary axis 78 '. It will be understood that washer 133 'and washer 132 provide an alternative fixing means on compression spring 360 and washer 132 shown in Figures 29 and 30.
With respect to the first group of internal components, the
108 support plate 70 'has a circular shape with a diameter substantially equal to the diameter of the rotor housing 4'. As in the prior art separator 2 ', the relative geometries are such as to allow the support plate 70' to locate on a shoulder facing down 148 'at a lower end of the rotor housing 4'. In this way, the lower open end of the rotor housing 4 'is closed by the support plate 70'. However, in the improved separator 2 ', the lower opening end of the rotor housing 4' contacts the upper side of the support plate 70 'and is provided with a circumferential recess 260 to receive an O-ring seal 262 (see Figure 34 ). It will be understood that the second O-ring seal 262 ensures a fluid seal between the rotor housing 41 and the support plate 70 '.
In addition, in the mounted separator 2 ', the radially outermost circumferential edge surface 630 (forming a reference surface) of the support plate 70' aligns in contact with a cylindrical inner surface 632 surrounding the lower open end of the housing. rotor 4 '. In this way, the support plate 70 'is laterally aligned in a desired final position relative to the rotor housing 4' (see Figure 13).
The support plate 70 'is also provided with a central circular opening which, in the mounted separator 2', is concentric with the rotor housing 4 '. In other words, in the mounted separator 2 ', the circular central opening of the support plate 70' is centered on the central geometric axis 64 'of the rotor housing 4'. Furthermore, as will be particularly evident from Figure 34 of the accompanying drawings, the base support unit 90 'is received in the central opening of the support plate 70'. The radially outermost part of the base support unit 90 'is fixed in relation to the support plate 70'. The radially innermost part of the base support unit 90 is located adjacent to the rotary axis 78 ’, but is not
109 fixed there.
As mentioned above, the first group of internal components also comprises a housing insert 72 'which is fixedly attached to the support plate 70'. As in the prior art separator 2 ', the housing insert 72' works to secrete clean oil gas that has been separated from it. The housing insert 72 'of the improved separator 2' also provides an outlet 150 'for clean gas, which seals directly to the cylindrical inlet portion 211 of the valve unit housing 12' (see Figure 15).
The housing insert 72 'is provided as a unitary molding of plastic material. However, when describing the housing insert 72 'below, the insert will be considered to comprise four parts: an outer deflector wall 264 having a frustoconical shape, a support wall 266 having a cylindrical shape, a segregating ceiling member 268 having a frustoconical shape -conical; and an outlet part 270 defining said insertion outlet 150 '(see Figures 27 and 28 in particular).
The segregating ceiling member 268 of the housing insert 72 'has a frusto-tapered shape and is supported on the support wall 266. The segregating ceiling member 268 is provided with a central circular opening which, in the mounted separator 2', has a central geometric axis coinciding with the central geometric axis 64 'of the rotor housing 4'. An elongated channel / recess 272 (see Figure 28) is provided on the upper surface of the segregating ceiling member 268. This channel / recess 272 defines a fluid path for clean gas that extends from an inlet 282 of the recess 272 to the part of outlet 270 (having a tubular shape) of the housing insert 72 '. Inlet 282 is defined by a circumferentially lowered part of an upper circular perimeter edge 274 of the segregating ceiling member 268. Inlet 282 is located generally diametrically opposite the outlet part 270 of housing insert 72 '. The aforementioned recessed part
110 of said perimeter edge 274 extends through an arc 280 of approximately 80 °, this arc being centered on said common geometric axis of the housing insertion opening. In alternative embodiments, an entrance to the fluid path can be defined by a recessed portion between 45 ° and 110 °. In the mounted separator 2 ', only a short distance spans the segregating ceiling member 268 from the end plate 86'. As a consequence, it is believed that most of the clean gas entering region 606 between the segregating roof member 268 and the end plate 86 'does so through the space between the aforementioned recessed part of said perimeter edge 274 and the end plate 86 ', with only a relatively small proportion of clean gas flowing into said region in addition to the rest of said perimeter edge 274.
It should be understood, therefore, that the space between the entire circumferential perimeter edge 274 and the end plate 86 'provides an entrance 610 for said region 606 between the segregating ceiling member 268 and the end plate 86', however due to a part longitudinal 612 (i.e., entry 282 for channel / recess 272) of this entry 610 has greater depth 613 (i.e., greater axial spacing between the perimeter edge 274 and the end plate 86 ') than other longitudinal parts of the entrance 610, a large proportion of clean gas flowing into said region 606 thus proceeds through said longitudinal part 612 having the greatest depth 613. The depth of the remaining longitudinal parts of said region entrance (610) is minimal, in order to minimize the flow of fluid through them and thus also minimize the passage of oil droplets through them.The depth of the remaining longitudinal parts can be between one tenth and met greater depth 613 and is preferably one third of said greater depth 613.
During use of the separator 2 ', the clean gas leaving the stack of separator disc 84' drains down in a rotating, spiraling motion
111 along the inner surface of the rotor housing wall 4 '. It should be understood, therefore, that the clean gas entering the aforementioned region 606 between the segregating ceiling member 268 and the end plate 86 'tends to proceed with a rotary swirl movement centered on the central geometric axis 64' of the rotor housing 4 '. However, the gas flow entering said region 606 via the inlet 282 is immediately guided towards the insertion outlet 150 'through the side walls 276, 278 of the elongated recess 272. This direction of the clean gas flow is also believed reduce the rotational movement of the clean gas immediately at the entrance of said gas within said elongated recess 272 via the recess entry 282. In this relation, it will be seen by Figure 28 of the attached drawings that the upstream part of the elongated recess 272 is curved ( side walls 276, 278 of recess 272, thereby aligning with the swirling inlet fluid to substantially minimize desirable pressure losses when the fluid initially impacts the side walls 276, 278) and progressively becomes straight when the fluid it moves downstream along the recess 272 towards the insertion outlet 150 '. It is believed that the immediate reduction of swirling motion in most of the clean gas entering the region between the segregating roof member 268 and the end plate 86 'significantly reduces pressure losses in the fluid flowing through this part of the separator 2' as compared to the prior art separator 2 described above.
It has been observed that clean gas that does not flow through inlet 282 but enters the region between the segregating roof member 268 and the end plate 86 'at other locations along the perimeter of the segregating roof member 268 will tend to flow through said region with a swirling motion until received by the elongated recess 272, after which the radially external side wall 276 in particular is believed to guide the fluid through the insertion outlet 150 'and will also reduce the movement in
112 swirl of said fluid.
The cylindrical support wall 266 is concentric arranged with the central circular opening of the segregating roof member 268 and projects downwardly from the underside of the segregating roof member 268. The diameter of the support wall 266 is smaller than that from the perimeter edge 274 of the segregating ceiling member 268. In the spacer mounted 2 ', a smaller downward facing circular edge 450 (see Figure 27) of the support wall 266 contacts the support plate 70' at a junction between them. The support wall 266 thereby supports the segregating ceiling member 268 on the support plate 701 and ensures a correct axial location of the segregating ceiling member 268 relative to the support plate 70 '. The support wall 266 is also provided with a plurality of cylindrical shoulders 452 each of which has a recess for threadedly receiving a fastener 74 '. In the mounted separator 2 ', each fastener 74' extends into one of said projections 452 under the support plate 70 'through an opening in the support plate 70'. In this way, the insert housing 72 'is fixedly attached to the support plate 70'.
The lowermost circular facing edge 450 of the support wall 266 is provided with a plurality of openings / recesses 454 positioned at various locations along said edge 450. As will be seen by Figures 27 and 34 in particular, the recesses 454 provide a space between the support wall 266 and the support plate 70 ', through which, during use of the mounted separator 2', the fluid can flow. Specifically, during use of the separator 2 ', separated oil flowing radially inward from the cylindrical wall of the rotor housing 4' along the support plate 70 'passes through the plurality of recesses 454. A proportion of clean gas also flows radially inward through the upper surface of the support plate 70 '(as will be understood by a skilled reader) and this fluid also flows through the plurality of recesses 454. This
113 fluid flow is indicated by arrow 188 ’in Figure 34.
The outer baffle wall 264 extends downwardly from the perimeter edge 274 of the segregating roof member 268. The baffle wall 264 has a frusto-conical shape diverging in a downward direction from the segregating roof member 268 towards the plate support 70 'of the mounted separator 2'. The diameter of the baffle wall 264 at an upper end thereof (and therefore the diameter of the perimeter edge 274 of the segregating ceiling member 268) is substantially the same as the other diameter of the separating disc stack 84 '. Due to the frusto-tapered shape of the deflector wall 264, the deflector wall 264 converges with the generally cylindrical wall of the rotor housing 4 'when moving in a downward direction. The cross-sectional area of the flow path between the baffle wall 264 and the rotor housing 4 'therefore reduces in the flow direction (i.e., in a downward direction). The lower free end 608 of the deflector wall 264 is located away from the cylindrical wall of the rotor housing 4 'and a distance 456 between 2 mm and 200 mm, and preferably 14' mm, above the support plate 70 '. This spacing of the outer baffle wall 264 of the rotor housing 4 'and the support plate 70' allows separate oil (or other separate material) and clean gas (which did not enter the first region inlet 610) to flow down along the cylindrical wall of the rotor housing 4 'and radially inward along the support plate 70' beyond the baffle wall 264 (including its free end). In doing so, the separated oil and clean gas flow through a second region 614 on an opposite side of the housing insert 72 'to the first flow region 606.
Also due to its frusto-conical shape, the outer deflector wall 264 diverges from the cylindrical support wall 266 when moving in a downward direction. The external baffle wall, member
114 with a segregating ceiling 268 and cylindrical support wall 266 define a generally annular shaped cavity 458 (see Figure 34) with an open lower end. The arrangement is so as to reduce the likelihood of separate oil flowing downwards along the rotor housing 4 'beyond the inlet 282 of the recess 272, only to subsequently flow upwards due to a fluid recirculation and, therefore, draining into inside entrance 282 contaminating the clean gas.
More specifically, although the relatively large spacing of the rotor housing 4 'and the upper end of the baffle wall 264 allows for easy separate oil entry between these details, the comparatively small spacing between these details at the lower free end of the baffle wall 264 reduces the ease with which the separated oil can be splashed or recirculated upwards between said free end and the rotor housing 4 '. In addition, any fluid recirculation adjacent the radially outer perimeter of the support plate 70 'will tend to result in separate oil flowing into the above-mentioned cavity 458. For example, the separated oil can flow upwards along the radially outer surface of the cylindrical support wall 266, just along the underside of the segregating ceiling member 268 and then down along the radially inner surface of the deflector wall 264. In due course, oil will likely fall from cavity 458 onto the support plate 70 'under the action of gravity. We observed that this recirculating flow path does not result in separate oil flowing upwards in such a way as to risk contamination of the clean gas flowing into the region between the segregating roof member 268 and the end plate 86 '. Thus, once the clean gas has flowed beyond the region inlet 606 (i.e., the inlet between the segregating roof member 268 and the end plate 86 ') towards the support plate 70', any subsequent recirculation of said gas back upstream towards said
115 inlet is prevented from resulting in recirculated gas (and gas droplets carried by it entering said region 606 through deflector wall 264, which effectively segregates (that is, maintains the separation of) said recirculated gas from said inlet.
The outlet part 270 of the housing insert 72 'is provided as an opening of a cylindrical tubular element on the upper surface of the segregating ceiling member 268 (and, more specifically, the opening into the recess 272 to receive clean gas) and extending in a generally radially outward direction through the supporting wall 266 and the outer deflecting wall 264. As will be particularly evident from Figures 13 and 14 of the accompanying drawings, the outlet part 270 is positioned above the edge facing downward from the wall. support 266. Therefore, in the mounted separator 2 ', the outlet part 270 is located above the support plate 70', so that the fluid can flow under the outlet part 270. Advantageously, separated oil can flow under the part outlet 270 and does not, therefore, tend to climb on the outer surface of the outlet part 270 towards the perimeter edge 274 of the segregating ceiling member 268, where Separated oil can easily contaminate clean gas by draining into recess 272 of housing insert 72 '. A free end of the outlet part 270 distal to its end opening into the recess 272 is provided with a support element 460, which projects downwards from the lower part of said free end, in order to contact the support plate 70 '. In this way, the support element 460 assists in maintaining a minimum spacing between the support plate 70 'and the outlet part 270 and also allows the support plate 70' to provide support for the free end of the outlet part 270.
During assembly, separator 2 'is attached to a turbine housing (not shown) in a similar manner as described above with respect to the prior art separator 2'. Specifically, the separator
The perfected 116 'is attached to a turbine housing by means of four threaded fasteners (not shown), each of which passes through a different four integral shoulder 284 with the lower end of the rotor housing 4 (see Figures 18 and 29 in particular).
It should be understood by those skilled in the art that, as in the case of the prior art separator 2, the support plate 70 '(and therefore all components of the first and second groups) is retained in the required position relative to the rotor housing 4 'due to the turbine housing pressing the support plate 70' for contact with the shoulder facing down 148 'when the rotor housing 4' and the turbine housing are fixed together. The support plate 70 'is essentially secured between the rotor housing 4' and the turbine housing 178 'by means of the threaded fasteners extending through four shoulders 284. When the threaded fasteners are tightened and the support plate 70' is brought in confinement with the shoulder 148 'as a consequence, the O-ring seal 262 in said shoulder 148' is pressed into the associated recess 260 and the second helical compression spring 130 'is compressed by the top support unit 50'.
In operation of the improved separator 2 ', a nozzle (not shown) of the turbine housing directs an oil jet over the turbine wheel 136', in order to rotate the turbine wheel in the direction indicated by arrow 134 '(see Figures 29 and 34). This rotation of the turbine wheel drives the rotation of the rotor unit as a whole in the direction of the arrow 134 'around the central geometry axis 64' of the rotor housing 4 '. In other words, the rotary axis 78 '; the upper rotor disc 80 '; the stack 84 'of separating discs 82'; the fan disk 240; the end plate 86 '; the splash guard disc 242; and the combined fan and turbine unit 88 '(i.e. collectively referred to here as the rotor unit) rotate together as a unitary assembly within the rotor housing 4' and relative to said housing 4 'and support plate 70'; the housing insert 72 '; and the
117 turbine housing.
The gas vented by the turbine housing, and requiring treatment by the separator 2 ', is introduced into the separator 2' via the fluid inlet 8 'located on top of the rotor housing 4'. As indicated by the arrow 68 'of Figure 34, the inlet gas penetrates the rotor housing 4' in a direction parallel to and in line with the central geometry axis 64 'and flows through three slits 66' in the top support unit 50 'before flowing into the inlet 600 of the unit and rotor beyond the twelve spokes 116' of the upper rotor disc 80 '. The rotational movement of the twelve rays 116 'also results in a lateral movement of the fluid located between said rays by the fact that said fluid moves tangentially from the circular path of the rays 116' and is effectively thrown out towards the cylindrical wall of the housing of rotor 4. In essence, the twelve spokes 116 'grant a cylindrical movement to the incoming gas.
When the incoming gas flows downward through the rays 116 ', 126' of the upper rotor disc 80 'and the separating discs 82', the gas is moved laterally to the cylindrical wall of the rotor housing 4 'via the spaces 602 between the adjacent separating discs 82 ', as shown by arrows 184' in Figure 34. Following this path, the direction of the fluid flow is changed by more than 90 °.
It should be understood that the spaces 604 between the radially outermost circumferential edges of the adjacent separating discs 82 'collectively represent an outlet of the rotor unit.
It should also be understood by those skilled in the art that oil droplets 186 'tend to assemble and form larger droplets when they move through the separating discs and are hurled onto the cylindrical wall of the 4' rotor housing. Once received by said cylindrical wall, the oil droplets 186 'tend to run downwards under the action of gravity on the support plate 70'. The circumferential border
118 external of the separator stack 84 'is sufficiently spaced inwardly from the cylindrical wall of the rotor housing 4' to allow oil droplets to run unimpeded down on said support plate 70 '. The O-ring seal 262 ensures that oil droplets cannot flow between the support plate 70 'and the rotor housing 4'.
It will be understood by those skilled in the art that, due to the rotary movement of the rotor unit, the fluid pressure within the rotor housing 4 'is greater at the peripheral edge of the separator disc stack 84' and support plate 70 'than in the region included by the support wall 266 and ceiling member 268 of the housing insert 72 'and the support plate 70'. As a consequence, there tends to be a flow of clean gas downwardly along the cylindrical wall of the rotor housing 4 'and radially inward along the support plate 70'. This flow of fluid tends to push oil droplets down along the cylindrical wall onto the support plate 70 below and then radially inward along the support plate 70 'through the openings in the support wall 266 of the housing insert 72 '. This flow of gas fluid is indicated by the arrow 188 ’(see Figure 34). The flow of fluid and gas moves radially inward across the upper surface of the support plate 70 'towards the central circular opening of the housing insert 72'. This flow through the support plate 70 'tends to push separate oil droplets through the support plate 70 towards the base support unit 90', through which said oil droplets pass. The rotating fan blades 140 'of the combined fan and turbine units 88' tend to decrease the static pressure of the turbine housing (to which the rotor housing 4 'is attached during use) in the region of the base support unit 90 'in order to pull the oil droplets through the base support unit 90'. The fan blades 140 ’then throw said droplets radially outward into the turbine housing, from where they can be taken back to the crankcase
119 engine. In the meantime, the gaseous fluid flowing through the support plate 70 'is pulled upward through the central opening of the insert housing 72' to pass radially outward between the extreme plate 86 'and the fan disk 240. The gaseous fluid can then let the rotor housing 4 'flow through said cylindrical part 211 of the valve unit housing 12', which is sealingly connected to the housing insert 72 'and passes through the housing insert outlet 150' and the housing outlet of rotor 10 '.
It will also be appreciated with reference to the accompanying drawings which, as well as flowing over the upper surface of the support plate 70 'and through the openings in the support wall 266 of the housing insert 72', part of the clean gas flows to said cylindrical part 211 via an alternative route between the lower side of the end plate 86 'and the upper side of the segregating ceiling member 268 of the housing insert 72'. This alternative route is indicated by the arrow 190 ’.
We have observed that, as in the prior art separator 2, the flow of oil through the base support unit 90 'of the improved separator 2' has a beneficial lubricating effect on the support unit. The top support unit 50 'is similarly lubricated by an oil mist that naturally occurs in the turbine housing and is transported upward to the top support unit 50' through the longitudinal flow path 92 'extending through the rotary axis 78 '.
The prior art ALFDEX ™ separator 2 or the improved separator 2 'described above can incorporate an alternative means for rotating the rotary axis 78' as shown in Figure 35 of the accompanying drawings. With reference to Figure 35, it will be seen that the Pelton wheel turbine previously described has been replaced by an electric motor without school 380, whose rotor 382 is attached to a lower end of the rotating shaft 78 ”under the support plate 70”. The electric motor 380 is shown in Figure
120 driving an ALFDEX ™ separator of the prior art 2. However, as will be understood by a person skilled in the art, the electric motor drive arrangement shown in Figure 35 can also be used with respect to the improved separator 2 'described above.
Referring to Figure 35, it will be seen that the electric motor 380 of the electric motor drive arrangement is located within a housing 384 which is attached to the rotor housing 4 by means of a plurality of fasteners with a 180 'screw thread (only one of which is shown in Figure 35). The motor housing 384 is comprised of upper and lower parts 386, 388, which are secured together with appropriate fastening means and with an O-ring seal 390 located at the interface between them. O-ring seal 390 prevents undesirable leakage into the space within housing 384 of dirt, water and / or other foreign matter located outside housing 384. In this way, electronic components (including printed circuit boards and / or other circuits) are isolated from material that can result in malfunction and subsequent malfunction.
The upper part 386 of the housing 384 is provided with a cylindrical wall projecting downwards 392 defining a central opening in said upper part 386. The cylindrical wall 392 is arranged to be located concentrically with the rotating axis 78 ”in the mounted separator. A 139 ”baffle washer is removed on the rotating shaft 78” by a 404 washer. Deflector washer 139 'thus presses upward against a radially internal support groove of the base support unit, as in the prior art ALFDEX ™ separator 2. Deflector washer 139 ”has a radially external perimeter edge radially away from the cylindrical wall 392, in order to allow contaminated oil to pass between them.
An upper end of another separate part 394 of the motor housing 384 (having a generally frusto-tapered shape) is
121 located at and sealed with a lower end of the cylindrical wall 392 of the upper part 386. The seal between the cylindrical wall 392 and the frusto-conical part 394 defines a closed-loop shape and is provided by means of another ring seal O 396. A lower end of the frusto-conical part 394 (having a larger diameter than its upper end) is sealed against the lower part 388 of the motor housing 384 by means of yet another 398 O-ring seal. This seal also defines a closed loop format.
Thus, on one side of the frusto-conical part 394, said part 394 and the lower part 388 thereby form a space in which the electric motor 380 is located and within which the lower end of the rotating shaft 78 ”extends. On the other side of the frusto-conical part 394, said part 394 and the upper part 386 and the rest of the lower part 388 form a fully closed and sealed space / compartment 406, in which electronic / electrical components (for example, a Circuit Board Form 408) are housed to supply electrical power and control signals to the electric motor 380. The compartment 406 is sealed from not only the exterior of the motor housing 34, but also from the space in which the electric motor 380 is located. Contaminated oil seeping through this space in use of the separator is therefore prevented from gaining access to the electronic / electrical components and causing them to malfunction.
In addition, the frusto-conical part 394 is provided with an opening (not shown) through which electrical wires 410 (connecting motor 380 and said electrical supply / control components) extend and into which said wires are sealed.
A connector 412 also extends through an opening 414 in the rotor housing 384 to allow one or more electrical wires (not shown), located outside the separator (for example, associated with a vehicle with which the separator is used) ), connect to
122 said electrical supply / control components housed within compartment 406. In other words, the electrical wire or wires may be provided with a plug to mechanically and electrically connect with connector 412. The wire or wires may contain electrical energy and / or control signals for the electric motor drive arrangement. Connector 412 is sealed to housing 384 in order to prevent unwanted foreign matter from entering compartment 406.
Although compartment 406 has a generally annular shape concentric with the separator rotor unit, it should be understood that compartment 406 can be of a different shape.
A stator 400 of the electric motor 380 is attached to the lower part 388 of the rotor housing 384. A radially internal part of said frusto-conical part 394, which seals with the cylindrical wall 392, defines an opening having a diameter substantially equal to the larger diameter. of the electric motor 380 stator 400.
During the use of a separator provided with the electric motor drive arrangement of Figure 35, an electricity supply is connected to the brushless electric motor 380, in order to operate its rotor 382 and thereby rotate the rotating shaft 78 ”. As explained above, the separated oil passes from the rotor housing 4 down through the base support unit. In a separator provided with the electric motor drive arrangement of Figure 35, this separate oil is ejected from the base support unit into the interior of the motor housing 384 and, more particularly, into the space within the cylindrical wall 392 the upper housing part 386. The separated oil then passes through the rotor 380 of the electric motor 380 and leaves the motor housing 384 via an orifice 402 located under the electric motor 380 of the lower housing part 388. The oil passing through the rotor 382 (or through a space between rotor 382 and stator 400) and coming in contact with said rotor 382 and the
123 stator 400 does not adversely affect the operation of electric motor 380 because the electrical wires of stator 400 are covered by a layer of epoxy lacquer.
With reference also to the manufacture of the improved separator 2 'and, in particular, the assembly of the top support unit 50' in the rotor housing 4 ', reference is now made to Figures 37 to 4' of the accompanying drawings. These Figures show a rotation welding process from the top support unit 50 'to the rotor housing 4' in a position that is in axial alignment with the base support unit 90 'when the support plate 70' is mounted on contact with the lower end shoulder 148 'of the rotor housing 4'. The fastening process ensures axial alignment of the top and bottom support units 50 ', 90', despite the variations in geometry resulting from a warping of the rotor housing 4 'after the injection molding of said housing 4'.
The process makes use of a rotating welding template 500 comprising a stator part 502 and a rotor part 504 rotatably attached to the stator part 502. The stator part 502 comprises a circular disc 506 having a diameter equal to the support plate 70 '. The geometry of the circular disc 506 is such as to allow said circular disc 506 to be located in contact with the rotor housing 4 'in the same way as the support plate 70' of the mounted separator 2 '(as shown in Figure 40) . The rotor part 504 comprises an axis 508 which extends through the center of circular disk 506 and is oriented perpendicularly to said circular disk 506. The axis 504 is fixed in relation to circular disk 506 by means of a support unit (not shown) ).
One end of the shaft 508 is provided with a head 510 for receiving the top support unit 50 '. The head 510 is provided as a circular disk concentric with the circular disk 506 of the stator part 502 and centered on the geometric axis, around which the rotor part 504 rotates. O
124 head diameter 510 is essentially equal to the diameter of the radially internal surface of the cylindrical wall projecting downward 58 'from the top support unit 50'. In this way, the cylindrical wall 58 'of the top support unit 50' can be located around the head 510 with little or no relative lateral movement between the top support unit 50 'and the axis 508. Relative rotational movement between the top support unit 50 'and the axis 508 are avoided by the projections 512 rising from the circular disk of the head 510. The head 510 comprises three projections 512 which are identical to each other and equispaced around the rotating geometric axis of the axis 508 The projections 512 are each of a partially circular shape and are positioned and sized to be located in the partially circular slots 66 of the top support unit 50 '. The projections 512 are substantially the same size and shape as said slits 66 'and, as such, the rotational movement of the top support unit 50' relative to the head 510 of the shaft 508 is substantially avoided when the projections 512 are received through said slits 66 (see Figures 37 and 38 in particular).
A second end of the shaft 508 distal to the end provided with the head 501 is provided with means 514 for connecting the rotor part 504 to a motor to drive the rotary movement of the rotor part 504 with respect to the stator part 502.
The rotation welding template 500 with a top support unit 50 'located on its head 510, is shown in Figure 39 of the accompanying drawings. With the top support unit 50 'located on the head 510, the shaft 508 and top support unit 50' are inserted into a rotor housing 4 'as shown in Figure 40. The circular disc 506 is located and in contact with the lower shoulder 148 'of the rotor housing 4'. More specifically, an outer circumferential edge surface 634 (forming a reference surface) of the
125 circular disc 506 aligns in contact with the cylindrical inner surface 632 surrounding the lower opening of the rotor housing 4 '. In this way, the lateral positioning of the top support unit 50 'in relation to the rotor housing 4' is determined. With the rotary welding template 500 located in this manner within the rotor housing 4 ', the rotational axis of the rotor part 504 coincides with the previously described central axis 64' of the rotor housing 4 '.
The rotor part 504 can be arranged in order to be movable with respect to the stator part 5021 in an axial direction, so that the top support unit 50 'can move from a first position, wherein said unit of support support 50 'is moved away from the upper part of the rotor housing 4', to a second position, in which the support unit 50 'is pressed in contact with the ridge 238 provided on the rotor housing 4' (see Figure 34). During the assembly of the top support unit 50 'in the rotor housing 4', the rotor housing 4 'is kept stationary and although the circular disk 506 of the stator part 502 is located in contact with the lower shoulder 148' of the rotor housing 4 ', the rotor part 504 is rotated at relatively high speed and moved axially further into the rotor housing 4', in order to bring a rotating top support unit 50 'in contact with said crest 238. The rotating top support unit 50 'is forcibly pressed against the ridge 238 in order to generate frictional heat and thereby melt the plastic material contact surfaces of the top support unit 50' and the ridge 238. While by pressing the support unit (50 ') against the ridge 238, the rotary movement of the axis 508 is quickly reduced and stopped in order to allow the support unit (50') and ridge 238 to join when the plastic materials melted cool. The top support unit 50 'and the rotor housing 4' are thus welded by rotation to each other.
Rotor housing 4 'can be kept stationary
126 during the rotation welding process by means of fasteners with screw thread extending through the shoulders 284 of the rotor housing 4 'and into a cylindrical mounting block 516 (see Figure 40).
Once the top support unit 50 'has been attached to the rotor housing 4', the rotary welding template 500 can be removed from the rotor housing 4 '. The top support unit 50 'is thus left correctly positioned and secured to the rotor housing 4' as shown in Figure 41 of the accompanying drawings. It will be understood that the top support unit 50 'is located in a position that is central to the lower circular shoulder 148' of the rotor housing 4 '. In this way, when the internal components of the separator 2 'are located within the housing 4', the contact of the support plate 70 'against said shoulder 148' ensures that the base support unit 90 'is also located centrally with said shoulder 148 '. The top and bottom support units 50 ', 90' are thereby axially aligned despite any previous warping of the rotor housing 4 'subsequent to injection molding.
The versatility of the improved separator is increased when compared to the separator 2 of the prior art, due to the fact that certain modules / components are interchangeable in different separating systems (see Figure 36). The ability of the rotor housing 4 '(i.e., a particular type of module) to receive different valve units 14' (i.e., different versions of another type of module) has already been discussed above. This modular approach is achieved by different versions of a given type of module / component (for example, a valve unit 14 ') having identical details to connect / interface with other modules / components. As an example, a separator system can potentially be used in one of several different valve unit versions, because these different versions are provided with common details
127 that allow union with the rotor housing 4 'even though the valve units may be different in many other respects. The table provided by Figure 36 shows how different components / modules of a separator system can be optionally provided with a component / module or exchanged for a different version of a component / module.
The present invention is not limited to the specific embodiments described above. Alternative arrangements and suitable materials will be evident to a reader skilled in the art.

权利要求:
Claims (8)
[1]
1. Gas cleaning separator (2 ') to separate a flowable mixture of substances of different densities, such as a gas and liquid, said separator (2') comprising:
a housing (4 ') defining an internal space, an opening to allow the flow of a fluid along a flow path between the exterior of said housing (4') and said internal space, and a shoulder (6 ') raising from the housing (4 ') and surrounding said opening, characterized by the fact that the shoulder (6') comprises a curved surface (221) extending into the opening, and a generally cylindrical wall (217), a free end of the which is provided with a circumferential edge (219) forming the curved surface (221), and the separator comprises a nipple (22 ') connectable to the shoulder (6'), so that an internal surface (216) of the nipple (22 ') combine with the curved surface (221) of the boss (6') to provide a curved surface for the flow path.
[2]
2. Separator (2 ') according to claim 1, characterized in that said curved surface (221) forms a closed circuit around the opening and extends into the opening, in order to reduce the opening area when moving through said opening from the outside of said housing (4 ') towards said internal space.
[3]
3. Separator (2 ') according to claim 2, characterized in that said curved surface (221) describes a partially circular line when seen in a cross section taken through a plane coinciding with a longitudinal geometric axis (64') through said opening.
Petition 870190070754, of 7/24/2019, p. 9/75
[4]
4. Separator (2 ') according to any one of claims 1 to 3, characterized in that the inner nipple surface (216) meets the curved surface (221) on an edge (229) of the shoulder (6 ') and, at this meeting point, be oriented tangentially to the curved surface (221).
[5]
Separator (2 ') according to any one of claims 1 to 4, characterized in that the nipple (22') additionally comprises a curved wall (235), configured to contact the curved surface (221) of the shoulder (6) ').
[6]
6. Separator (2 ') according to any one of claims 1 to 5, characterized in that the nipple (22') is connectable to the shoulder (6 ') in any rotational orientation.
[7]
7. Separator (2 ') according to claim 6, characterized in that the nipple (22') is connectable to the boss (6 ') by welding by rotation.
[8]
8. Method for assembling a gas cleaning separator (2 '), wherein the separator (2') is as defined in any of claims 1 to 7, characterized in that it comprises the step of connecting the nipple (22 ' ) to the shoulder (6 ') by welding by turning.

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CN111997712A|2020-09-04|2020-11-27|上海弗列加滤清器有限公司|Filter element assembly and rotary oil-gas separator|

法律状态:
2019-01-22| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2019-05-28| B06T| Formal requirements before examination [chapter 6.20 patent gazette]|

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2019-08-27| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2019-10-08| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 10 (DEZ) ANOS CONTADOS A PARTIR DE 08/10/2019, OBSERVADAS AS CONDICOES LEGAIS. (CO) 10 (DEZ) ANOS CONTADOS A PARTIR DE 08/10/2019, OBSERVADAS AS CONDICOES LEGAIS |

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2020-01-14| B16C| Correction of notification of the grant [chapter 16.3 patent gazette]|Free format text: REF. RPI 2544 DE 08/10/2019 QUANTO AOS INVENTORES. |

优先权:

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申请号 | 申请日 | 专利标题

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PCT/SE2009/050892|WO2011005160A1|2009-07-10|2009-07-10|Gas cleaning separator|

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