The Development of High Efficiency Crankcase Ventilation and Oil Mist Separator for a Heavy-Duty Diesel Application

Both current exhaust emission legislations and continuously growing customer demand of less oil consumption drive the diesel engine manufacturers to develop more efficient crankcase ventilation and oil mist separation systems. In recent years, integrated design concepts are also considered for almost all sub-systems to achieve compact solutions fulfilling the tightened packaging requirements and more challenging cost targets.

This paper presents crankcase ventilation and oil mist separator unit of new generation Ford Otosan Ecotorq Heavy Duty Diesel engines and all work to reach its final configuration, the three-layer filter element with an integrated impactor design. The unit has a compact design as it is integrated to engine valve cover. Challenges brought by the packaging boundary conditions in draining the collected oil by high efficient media are overcome through the extensive experimental development work, which includes tests on special rigs, engines run on dynamometers and fleet tests. Effects of different media types, deflector and impactor designs, oil repellent chemicals and pre-filters are discussed based on the test results.