Rotera Disc Stack Technology
The technology consists of a rotor with conical discs stacked onto each other, which is driven either electrically or hydraulically. Blow-by gas gets pushed – and due to rotation also sucked- – into the rotor and forced through the gaps between the single discs of the stack. Due to flow and centrifugal force, the captured particles move towards the surface of the next located rotating disc and coalesce with each other. The separated particles get forced to the outer edge of each disc and are thrown to the inner wall of the rotor.
Clean gas is vented either to the atmosphere (OCV) or back to the engine intake manifold (CCV), whereas the separated oil is fed back to the oil recirculation system. For off-highway applications, which are running continuously over longer periods, Rotera can design specific drain systems to fulfil any demands.
New Disc Stack Technology combined with filter element
Our Disc Stack Separation Technology provides one of the highest separation rates possible. To reach even higher efficiency rates, our latest patented innovation that combines Disc Stack Separation Technology with a highly efficient downstream filter ensures close to particle free emissions where even most of the finest particles (<0.6μm) will be removed. The solution is developed to support our global customers to meet stricter emission regulations demanded by commissions such as European Commission and CARB.
The filter has regenerative properties and can discharge itself to some extent when the engine is off, thereby feeding the separated oil back into the oil circuit. The proprietary filter design is customer-specific and adapted to the installation space, composition of the blow-by gas, particle sizes, temperatures, and the desired service lifetime, among other custom requirements.
The disc stack separators can be either driven by a BLDC motor or by hydraulics. The robust BLDC motor is designed as a lifetime component and includes electronics to communicate with the ECU. It can be powered by 12V or 24V and communicates via PWM or CAN as standard for heavy-duty and commercial vehicles. Our hydraulic drive system is a patented innovation based on the HERON principle with a contactless seal between the drive and rotor chamber. The system is fed by engine oil from the oil circuit, which flows through the hollow drive axle, goes up to the turbine, and out through the radially located nozzle. When it passes through the nozzle, the disc stack separator begins rotating because of the repulsion effect and can reach speeds up to 12,000 rpm. The advantage with the hydraulic drive is that it is insensitive to vehicle vibrations, a common issue of the hydraulic drive solutions competitors use.
Patented Guiding Ribs
To prevent separated oil particles from being accompanied by the purified gas out of the separator, Rotera developed and patented unique guiding ribs. In combination with the stream of the rotating gas inside the separation chamber, these ribs ensure that the separated oil droplets are moved down to the bottom of the rotor chamber where the oil is then ejected and channelled back to the engine oil circuit.
For all type of fuels
Modern engines and vehicle models have varying and complex requirements for crankcase ventilation systems. That’s why Rotera specializes in customized designs, products, and solutions. Our systems for crankcase ventilation were originally designed for traditional combustion engines but can be adapted to the specific demands of engines running with natural gas, bio-fuels, or e-fuels such as hydrogen.