Electrically Driven Disk Separator for Passenger Car Applications.
All around the world, new emission standards are imposing rigorous requirements on engine development. Low-emission gasoline and diesel engines with modern combustion technology make excellent oil separation values a necessity for the crankcase ventilation. Consequently, the technological trend is towards active ventilation. The electrically-driven Blue.tron disk separator is currently the most advanced crankcase ventilation device. It offers high-efficiency oil separation and active blow-by conveyance for crankcase ventilation. Reduction of the oil input in the engine intake system enables higher charge air pressure level, which can be utilized to boost engine performance and efficiency.
According to EU-legislation the crankcase pressure shall be below ambient pressure to inhibit exhaust gases leaving the engine’s interior. To fulfill this demand a crankcase ventilation system is preferable that does not throttle the flow off the crankcase into the intake system of the engine and the Hengst Blue.tron even supports this flow. So legal compliance is guaranteed and along with it the engine’s oil return from turbocharger, valve stem seals and the oil separator itself is enhanced.
Fine oil aerosols occurring in high performance combustion engines can have multiple negative impacts. The best-known effect is compressor coking of Diesel engine turbochargers leading to loss of engine power and increased fuel consumption. Another negative effect is the low-speed pre-ignition phenomena which can be an oil aerosol induced effect leading to severe engine damages. Hengst Blue.tron separates those fine oil droplets to the highest extent and ensures durable high performance engine operation.
The electric drive of the Hengst Blue.tron is designed to gain maximum performance, control, efficiency and installation flexibility. The rotational speed possible with the electric drive is 50% higher compared to a hydraulic drive. The rotational speed of the disk separator is easily controllable to adapt to different engine operation points and utilize least electric power. And the Blue.tron system can be placed freely in the engine bay omitting large hoses and cross sections for oil supply and return as they are required for hydraulic drive systems.
The Blue.tron modular system – basic variants:
Hengst Filtration offers basic sizes as well as customized disc separator sizes.
Blue.tron modular system – add-ons:
The basic variants can be supplemented by various add-ons, or different versions enable customer-specific requirements to be met.
- Pressure Control
The active crankcase ventilation system Blue.tron by Hengst is available as an off-the-shelf component in two sizes capable to clean blowby flowrates of up to 160 l/min (Blue.tron 160) or up to 240 l/min (Blue.tron 240). Basically, the Blue.tron 160 is designed for gasoline engines up to 3 liters displacement and Diesel engines up to 2.5 liters displacement, whilst Blue.tron 240 works fine with gasoline and Diesel engines of up to 4 liters displacement.
Both versions are set up with an electric drive working with 12V and a speed control via LIN protocol. The Blue.tron system has an operating temperature range of -40 … 135°C which works perfect for most engine bay applications. It will be a pleasure for us to help you select the right Blue.tron size for your application.
Our Blue.tron off-the-shelf separators come with a variety of possible fixation possibilities. Due to the basic setup with a plastic housing made of resistant PA material we recommend the use of metal bushings and compression limiters. Those bushings are available with spacers to assembly Blue.tron to a flat surface or without spacers to bolt it onto screw bosses.
All bushings can be mounted in two directions to have the disk separator outlet in a position most favorable for your application.
A universally applicable separation system requires large flexibility in connections. To cover this demand the Hengst Blue.tron is equipped with a freely rotatable raw gas port, an oil drain stub that can be flipped within two positions, doubled clean gas ports and the elctric connection rotateble in 120° increments.
Along with the flexibility to have the pressure regulation valve either on the left or right side of the separator housing an almost indefinite number of possible variations is given.
Oil separation performance and low differential pressure are two basic features a good separation system needs to have and the Hengst Blue.tron disk separator definitively has. To ensure easy installation to any application a pressure regulation valve is a necessary add-on to safeguard proper crankcase pressures even in weird events such as fully stuck or wet air filters.
The Blue.tron off-the-shelf separator comes in two configurations for use in Diesel engine applications with a simple clean gas connection upstream compressor or for use in gasoline engines with the capability of the clean gas pipe to be connected downstream the intake throttle.
The pressure regulation valve installed in the Blue.tron off-the-shelf separators are ambient pressure referencing membrane valves with specific material choice for gasoline and Diesel applications.
Easy installation of the Hengst Blue.tron off-the shelf separator is ensured by availability of different styles of stubs whether concerning orientation or connector style. In addition to regular hose stubs, VDA and Norma quick connectors are available as well as straight and 90° angled stubs.
All stubs can be rotated in the separator‘s housing to cope with every flow routing desired.
Blue.tron – the most important advantages at a glance:
High engine efficiency, low emission level and emission stability throughout the complete product life.
High efficiency aerosol particle separation up to 95% @ 0,3 µm safeguarding the intake system from deposits, the engine from irregular combustion and the environment from pollution.
Active blowby flow leading to sub ambient crank case pressures gives you legal compliance, proper turbo charger oil return and ability for 24/7 engine operation.
ECU interface using LIN bus enables onboard diagnosis (OBD) and disk separator speed control for adaptation of cleaning efficiency, crank case pressure and energy consumption.
Easy installation for existing and new engines due to electric drive, large flexibility of design and connections and ambient pressure referenced regulation valve preinstalled. No engine hardware or software adaptation necessary.
Fit for future combustion processes with the use of low-carb fuels, water injection, EGR utilization and Miller cycles require adapted crank case ventilation systems.