Abstract:
A modular cyclone precleaner system includes one or more standardized and reusable modular cyclone blocks configured in parallel. The modular cyclone blocks are provided as components designed for reuse across differing precleaner systems for potentially different precleaner applications, providing standardized component building blocks and reducing manufacturing cost. The modular cyclone blocks are designed to be selectively combinable to provide a cyclone precleaner system having the required gas flow characteristics and particulate removal capabilities required for any given precleaner application. The precleaner system includes a housing that is sized for at least one given precleaner application and adapted to supportively receive the selectively combined modular cyclone blocks for the application.

Description:
TECHNICAL FIELD 
       [0001]    The present invention generally relates to modular cyclone precleaner systems built upon one or more standardized modular blocks of cyclone separator elements arranged to process flow in parallel. The invention also relates to a method for producing the precleaner systems built from these modular cyclone blocks. 
       BACKGROUND OF THE INVENTION 
       [0002]    Cyclone separators frequently find application in the removal of solid particulates from air streams, examples including the intake systems of commercial and construction vehicles as well as air compressor intakes and various manufacturing and chemical processes. The cyclone separators of interest typically include a swirl inducing vane structure in the intake portion of the body. The swirl inducing vane structure induces a swirl or spin to the air stream that causes the outwards migration of entrained dust and particulates towards a flow tube wall due to the action of centrifugal forces on the swirling particulates. The cleaned gas then flows out of the center portion of the separator into a clean air take-off tube while centrifugal forces in the swirling gas cause dust and particulates to be ejected outwards through an annular gap or window in the wall of the cyclone separator. 
         [0003]    Multicell cyclone separators are known in the art. For example, U.S. Pat. No. 6,884,273 discloses a multicell cyclone separator having groups of cyclonic cells arranged in parallel. 
         [0004]    U.S. Pat. No. 4,008,059 discloses a cyclone separator for removing particulates entering an engine air cleaner. 
         [0005]    U.S. Pat. No. 4,537,608 discloses a system for removing contaminant particles from a gas stream that includes a plurality of vortex air cleaners (cyclone separators) arranged side by side in two perpendicular rows. 
         [0006]    US Publication 2008/0209869 A1 discloses a gas intake zone of a filter housing, which serves as a prefilter that includes a plurality of cyclone collectors arranged side by side. The cyclones are provided as a custom application specific unit. 
         [0007]    As can be understood from the above, many varieties of cyclone precleaners are known to those skilled in the art. As can also be seen from the above prior art as well as the current state of the art, known precleaners utilize either individual cyclone cells or alternately a custom made cyclone block of cells in a custom housing, both being designed and adapted for a specific intended application. These individual cyclone cells are typically injection molded and subsequently pressed into steel or plastic plates. Typically these cells eject contaminants through an annular gap or radially outwards through a window or opening in the cyclone cell. 
       SUMMARY OF THE INVENTION 
       [0008]    In one aspect of the invention a modular cyclone precleaner system includes at least one modular cyclone block configured to remove particulates from an air stream. In the present invention, modular cyclone blocks are provided as components designed for reuse across differing precleaner systems for potentially different precleaner applications. Modular cyclone blocks include one or more cyclone separator cells arranged in parallel and configured to swirl a gas stream for removal of contaminants by centrifugal force. Each cyclone separator cell has a cyclone housing with a particulate discharge port for particulates removed from the intake gas stream. Modular cyclone blocks are configured into standardized sizes and cyclone cell configurations (number and type of cyclones on a block). The modular cyclone blocks are designed to be selectively combinable to thereby provide a cyclone precleaner system having the required gas flow characteristics and particulate removal capabilities required for any given precleaner application. The precleaner system may include a housing that is sized for at least one given precleaner application and adapted to supportively receive the selectively combined modular cyclone blocks for the application. The modular precleaner system is configurable and adaptable to other applications by adapting the housing while reusing a sufficient number and type and sizes of modular cyclone blocks, as determined by the requirements of the application. 
         [0009]    In another aspect of the invention, the housing further includes a first housing half and a symmetric mating second housing half. The housing halves, when mated, are configured and adapted to form a particulate collection chamber therein and a particulate outlet in the housing. The housing is configured to capture particulates from the discharge ports of the cyclone separators. Advantageously, the housing halves are symmetric and interchangeable, enabling the halves to be produced by the same mold. 
         [0010]    In another aspect of the invention, at least one of the modular cyclone blocks includes a ramped skirt provided on an interior facing portion of the block. The ramped skirt is configured to channel particulates towards a side region of the modular cyclone block and therefore away from the cyclone separator cells of the modular block. 
         [0011]    In another aspect of the invention, the cyclone separator cells each include an upstream end for receiving a particulate laden intake gas stream, a downstream end for discharging a cleaned output gas stream and a swirl inducing structure for imparting centrifugal forces onto the particulates in the intake gas stream. 
         [0012]    Additionally, a method is disclosed for producing a precleaner system from a defined universe of modular cyclone block types. The method includes choosing types and quantities of modular cyclone blocks for the precleaner from the predefined universe of blocks according to air flow and particulate removal requirements of an application. Then a housing is designed and produced to supportively receive the chosen modular cyclone blocks. The modular cyclone blocks are then installed into the housing to form a completed modular precleaner system. 
         [0013]    The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      FIG. 1A  is an exploded view of one embodiment of a reusable modular cyclone block having a plurality of cyclone separator cells and a ramped skirt feature for deflecting debris, consistent with the present invention; 
           [0015]      FIG. 1B  depicts an inside perspective view of one embodiment of an upstream portion of the upstream support plate and modular cyclone cells as in  FIG. 1  illustrating the ramped skirt feature as well as the particulate discharge portions of the cyclone separator cells, consistent with the present invention; 
           [0016]      FIG. 2  illustrates a perspective view of an upper portion of one embodiment of an assembled modular cyclone block, consistent with the present invention; 
           [0017]      FIG. 3  illustrates an exploded/assembly view of one embodiment of the modular cyclone precleaner system, consistent with the present invention; and 
           [0018]      FIG. 4  illustrates a perspective view of an exemplary embodiment of a fully assembled modular cyclone precleaner system, consistent with the present invention. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0019]    The present invention generally relates to modular cyclone precleaner systems built upon one or more standardized reusable modular blocks, each block having one or more cyclone separator elements arranged to process an air stream in a parallel fashion for removal of entrained particulates. In the current state of the art, cyclone precleaners utilize either individual cyclone cells or a custom cyclone block of cyclone cells in a custom housing, typically directly attached to the air filter housing. In the prior art the precleaner and cyclones are custom shaped and sized to meet the geometry, airflow and particulate removal requirements of each intended application. While such known designs provide a workable solution, custom precleaner designs of the prior art suffer from significant tooling and production costs. Further, these known custom designs limit the reuse of precleaner system components between differing applications. 
         [0020]    To overcome these issues advantageously, the present invention provides a modular cyclone precleaner system in which precleaner systems for new applications are built up from standardized pre-engineered modular cyclone blocks with each block having one or more cyclone separator cells. Advantageously, each new precleaner application may utilize a custom housing while precleaner system cost reductions and production efficiencies accrue from the reuse of standardized modular cyclone blocks. The reuse of standardized modular cyclone blocks permits tooling and development costs to be reduced and also spread over a greater number of precleaner designs and customer applications. 
         [0021]    In the present invention standard size modular cyclone blocks may be produced and then made available from production stores as “off the shelf” components. It is anticipated and intended that modular cyclone blocks be provided in a variety of sizes, differing according to desired flow rate, particulate removal requirements, physical block size, materials and other factors as required to meet a wide variety of specifications of precleaner applications. A specific precleaner housing is designed to receive the required number and type of modular cyclone blocks. The housing may be a customized housing designed and adapted to fit the geometric requirements of the intended application, adapting standardized modular cyclone blocks to fit the specific geometric interface requirements of the end application to provide a successful precleaner unit. 
         [0022]      FIG. 1A  illustrates an exploded view of one embodiment of the present invention in which an exemplary standardized size modular cyclone block  12  has sixteen cyclones separator cells arranged to process particulate laden air flow in parallel and includes a ramped skirt  20  for deflecting debris from the vicinity of the cyclone separator cells  14  (see  FIG. 2 ). In the specific aspect of the invention illustrated in  FIG. 1A , the circular flow tubes  22  are provided on and formed or molded in one piece with the upstream support plate  26 , such as by an injection molding process. In other aspects of the invention, the complete cyclone separator cells or cell components such as the circular flow tubes  22  may be molded separately and then secured to the upstream support plate  26  by any variety of means known to those skilled in the art, including adhesives, friction welding, laser welding or by a snap-in insertion method. 
         [0023]    As illustrated in  FIG. 1A , each cyclone cell includes a particulate discharge port  28  through which particulates removed by the cyclone cell  14  are forcibly ejected due to the action of centrifugal force on the swirling gas stream in each cyclone cell  14 . 
         [0024]    In the specific illustrated embodiment, the modular cyclone block  12  includes a downstream plate  30  onto which are formed a plurality of clean air take off tubes  32 . Each tube  32  is sized and axially aligned with its corresponding circular flow tube  22  so as to be axially received at least partially into the interior of its corresponding circular flow tube  22 . In  FIG. 1A  the clean air take off tubes  32  are formed or molded in one piece with the downstream support plate  30 , such as by an injection molding process. In other aspects of the invention, the clean air take off tubes  32  may be molded separately and then secured to the downstream support plate  30  by any variety of means known to those skilled in the art, including adhesives, friction welding, laser welding or by a snap-in insertion method. In other embodiments, complete cyclone cells may be provided and individually secured to the downstream support plate  30  by any variety of means known to those skilled in the art, such as the means described above. 
         [0025]      FIG. 1B  depicts an inside perspective view of one embodiment of the upstream support plate  26  including the circular flow tubes  22  of the modular cyclone cells  14  as in  FIG. 1A .  FIG. 1B  more clearly illustrates the ramped skirt feature  20  as well as the particulate discharge ports  28  of the cyclone separator cells. In the illustrated embodiment, the ramped skirt  20  is provided between the two top-most cyclone separator cells and is smoothly formed to bridge between and tangentially intersect the topmost circular flow tubes  80 . Advantageously, the horizontal location of cyclone separator cells (indicated by circular flow tubes  22 ) in neighboring columns are horizontally offset or staggered to provide a higher flow capacity in a smaller size block while additionally providing an angled slope to the ramped skirt  20  so as to aid in shedding downwards falling debris impinging upon the ramped slope  20  towards a side (in  FIG. 1B  this would be the nearest side to the observer) of the modular cyclone block  12 . 
         [0026]    In the illustrated embodiment, the upstream support plate  26  includes a seal flange  68  provided circumferentially around the perimeter of the upstream support plate  26 . Advantageously, a step  72  is provided on boundary between the seal flange  68  and the upstream support plate  26 , the step permitting the upstream support plate to be closely fitted into a modular cyclone block receiving opening in the precleaner housing (such as the housing illustrated in  FIG. 3 ). While the step  72  and seal flange  68  are presented as the exemplary attachment means in  FIG. 1B , the invention is not limited to use of the step  72  and flange  68  to sealably attach the upstream support plate to the downstream plate  30 . Other sealable attachment means known to those skilled in the art may be used without deviating from the teachings of the present invention. 
         [0027]      FIG. 2  illustrates a perspective view of an upper portion of one embodiment of an assembled modular cyclone block  12 , consistent with the present invention. The cyclone separator cells  14  are shown in an assembled state with portions of the clean air takeoff tubes  32  received into an interior portion of the circular flow tubes  22 . Visible near the upstream support plate  26  are components of the swirl inducing structure  16 , depicted as an air directing vane structure provided in the interior of the circular flow tubes  22 . Also visible is a seal flange  70  provided circumferentially around the perimeter of the downstream support plate  30 . Advantageously, a step  74  is provided on boundary between the seal flange  70  and the downstream support plate  30 , the step permitting the downstream support plate  30  to be closely fitted into a modular cyclone block receiving opening in the precleaner housing, (such as the housing illustrated in  FIG. 3 ). The ramped skirt  20  as well as a portion of the swirl inducing structure  16  as provided in an upstream end  24  of the cyclone separator cells  14  is also visible. As noted earlier above, the invention is not limited to use of the step  72  and flange  68  to sealably attach the upstream support plate to the downstream plate  30 . Other sealable attachment means known to those skilled in the art may be used without deviating from the teachings of the present invention. In alternate embodiments is it envisioned that the attachment means may include vibration welding, hot plate welding, ultrasonic welding, infrared welding as well as adhesives, to name only a few. 
         [0028]    As further illustrated in  FIGS. 2 ,  1 A and  1 B, each assembled cyclone cell  14  includes a particulate discharge port  28  through which particulates removed by the cyclone cells  14  are ejected due to the action of centrifugal force on the swirling gas stream. Such particulates are directed by a housing discussed with  FIG. 3  below. 
         [0029]      FIG. 3  illustrates an assembly view of one possible exemplary embodiment of a modular cyclone precleaner system  10 , consistent with the present invention. The precleaner system  10  includes an exemplary housing  34  configured to receive one or more modular cyclone blocks (four blocks in the illustrated embodiment). Cyclone blocks may be, for example, variations of exemplary modular cyclone block  12  discussed earlier. As discussed earlier, reusable modular cyclone blocks may be provided in various sizes having differing arrangements and types of cyclone cells designed to meet airflow and particulate removal requirements. Embodiments of the invention are not limited to configurations shown in the illustrations as the illustrations are provided solely to provide the reader with one exemplary configuration for better understanding of the invention. Modular cyclone blocks may be provided in any suitable size for embodying any desired number of cyclone separator cells  14  into a modular reusable unit in standardized sizes. The housing  34  may alternately be configured to receive modular cyclone blocks of two or more sizes, or alternately all modular cyclone blocks may be of the same shape and size such as in the exemplary illustration of  FIG. 3 . 
         [0030]    Preferably, the housing is formed of two half housing portions  36  and  38  with each half housing portion having a symmetric design such that both housing halves  36  and  38  may be formed or molded using the same tool or mold, thereby reducing production tooling costs for low volume production programs. In the embodiment illustrated in  FIG. 3 , the housing halves  36  and  38  may mount together along mating flanges  40  and  42  to define a particulate collection chamber  76  having a circular outlet opening  48  configured to retentively mount a scavenge port  44  or aspirator port used to remove separated particulates from the modular cyclone precleaner system  10 . The scavenge port  44  includes a circumferential capture groove  50  configured to receive and mountably engage the housing halves  36  and  38  along the rim  78  of the circular outlet opening  48 . In some embodiments, the scavenge port  44  could be split into two portions with one of each portion included in each housing half  36 ,  38 . 
         [0031]    In an alternate embodiment, housing half  36  may be replaced by cutouts provided in the body exterior or sheet metal of the vehicle (for example a tractor), the cutouts configured to receive the first cyclone blocks  52 . In this alternate embodiment, the second housing half  38  mounts onto the inside surface of the vehicle exterior and is aligned to engage the first cyclone block half  52  with the second cyclone block half  54  secured to the second housing half  38 . 
         [0032]    After the housing halves  36  and  38  are assembled to form the housing  34 , individual modular cyclone blocks  12  (see  FIG. 2 ) may be secured to the housing to form a finished modular cyclone precleaner system  10 . As discussed earlier, advantageously components such as the modular cyclone blocks  12  and the scavenge port  44  or aspirator port can be shared across differing modular cyclone precleaner systems to minimize tooling costs and provide standardization of reusable components. 
         [0033]    In at least one embodiment of the invention, the removable modular cyclone blocks  12  may be individually and removably secured to the housing  34  using any of a variety of fastening devices  56 , such as threaded fasteners such bolts and screws, twist lock clamps, any of a variety of clips, etc as would be known to one skilled in the art without deviating from the disclosure of the present invention. In at least one embodiment, fastening devices  56  may comprise T-handled bolts (or T-bolts). T-bolts  56  each have an elongated cylindrical body having a threaded portion  60  provided at one end and a T-handle  58  provided at an opposing end. In the exemplary embodiment depicted in  FIG. 3 , the second cyclone half block  54  includes a T-bolt engagement member  64  secured thereto, such as onto the downstream support plate  30 . The T-bolt engagement member  64  includes a threaded receptacle  66  sized and configured to threadably engage the threaded portion  60  of the T-bolts  56 . The first cyclone block half includes an aperture  62  sized, configured and aligned to receive a portion of a T-bolt  56  therethrough so as to removably and mountably engage the T-bolt engagement member  64 . The handle  58  of the T-bolts  56  permit the T-bolts to be tightened by hand so as to compressibly mount the first  52  and second  54  block half portions together and onto the housing  34  to form an assembled modular cyclone block  12  (as depicted and discussed with  FIG. 2  earlier) mounted to housing  34 . The T-bolts  56  may also be operated to permit removal of at least one of the cyclone block halves ( 52 ,  54 ) for servicing. 
         [0034]      FIG. 4  depicts a perspective view of a fully assembled modular cyclone precleaner system  10 , assembled as discussed with  FIG. 3  above. 
         [0035]    The modular cyclone precleaner system  10  may be used in conjunction with an air cleaner/air filter assembly. In other applications, the modular cyclone precleaner system  10  may be utilized separate from an air cleaner or air filter, such as in certain dust removal and sweeper applications. Typical applications for the modular cyclone precleaner technology include, but are not limited to, on and off highway engines, compressors and stationary engines. These applications generally have smaller production volumes, which limit the amount of the tooling investment for a successful acquisition of business in a competitive bidding environment. The modular cyclone precleaner technology of the present invention enables the use of modular standardized components across several different applications, with differing vehicles and customers while also allowing each customer to have a custom solution that meets their specified requirements at reduced cost when compared to prior art systems. Advantageously, the modular cyclone precleaner system  10  allows the flexibility to select and configure the first and second cyclone block halves ( 52  and  54 ) to meet a wide variety of packaging requirements. 
         [0036]    In one aspect of the invention, a ramped skirt  20  may be provided over cyclone separator cells positioned at the upper portion of the modular cyclone block  12 . The ramped skirt  20  is configured to channel particulates to the side of the modular cyclone block  12  to be carried away to the outlet opening  48  of the housing  34 . In  FIG. 2  the particulates would be channeled to the right side of the modular cyclone block  12  and away from the cyclone separator cells  14  in the block  12 . Advantageously, the ramped skirt  20  helps to eject larger particulates and debris as may be encountered in agricultural or construction applications. Advantageously, the ramped skirt  20  facilitates the stacking of additional modular cyclone blocks  12  one above the other by deflecting particulates falling from other modular cyclone blocks. 
         [0037]    While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims.