2/6 rod bearing flow tests
#151
Risking reading too much into the tea leaves, I spent some time last night trying to reverse engineer the "active scavenge" system that Greg has advocated as the "racing" cure of the 928 oiling problems. I used the internet as the source, mainly photos by Rob and the various written comments posted by multiple people here on the RL. Of course, much of the system is proprietary and not disclosed, so I had to rely on my imagination heavily. Therefore, what I ended up as a result may or may not resemble what Greg installed on Rob's car.
With that explanation and keeping in mind that I've used my imagination to fill in a ton of blanks, here's what I came up with:
Attachment 687947
Since this is just a figment of my imagination, I will call the above-described system the "prankcase" evacuation system to differentiate it from anything that Greg may have actually installed on Rob's car.
Greg or Rob may
- choose to confirm that this prankcase system describes their system,
- may choose to deny that it describes their system with an explanation of what parts I just imagined,
- may choose to just deny that it describes their system without any explanation,
- or may choose to simply ignore this post.
I am obviosuly fine with any of these options, since it's their proprietary system and they are not obligated to tell me or the world anything about it. Any comment from them would be just intellectual charity. I'll just proceed to comment on the prankcase system that I imagined regardless of all this.
First, the prankcase system has a four stage scavenge pump with a single exit manifold, manufactured by Bill Dailey. The exit manifold is plumbed back to the pan. The four pickups are at the corners of the heads. The "secret sauce" parts under the valve cover scavenge near the corner head drains. In addition, the prankcase system has one of the valve covers hooked up to the oil filler neck and the other valve cover hooked up to the port between the knock sensors. The two remaining valve cover ports are hooked into the Provent via a T-fitting. The Provent drains oil to a T-fitting which is connected to one of the pump scavenge lines coming from the cam covers and going to the pump suction side. The Provent gas extraction port is connected to the intake manifold. The intent of the system is to use a pump to remove oil from the heads and return it to the sump.
Is everyone following?
Here's my mini-design review.
Positives:
+ I like the idea of venting the block from the middle of the valley. This should help reduce the need for the crankcase pulses to communicate thru the heads via the head drains.
+ I like the use of Provent as part of the system to reduce oil ingestion.
+ I like the fact that the pump outlet doesn't drain to valve cover or the oil filler neck but instead drains directly to the sump.
Negatives:
- The prankcase system scavenges the head oil drains from the top. In my opinion, it would be more effective to scavenge those from the other end of the drain channels, that is near the bottom of the block. This would avoid the active scavenge system actually pulling oil up into the heads that would've otherwise stayed in the crankcase.
- Mechanical scavenge pumps often scavenge a lot of gas as well as a lot of oil. It would be better to run an air-oil separator between the pump outlet and the sump.
- The prankcase system uses a T-fitting on one of the scavenge lines from the heads and connects that to the Provent. This has two undesirable effects. Since oil is heavier than gas, this pump stage scavenges gas only when either the Provent or the head pickup see gas. It scavenges oil only when both the Provent and the cam cover pickup see oil.
- The second undesirable effect of the scavenge line T-fitting is that the scavenge pump can easily pull a large vacuum into the Provent. This will likely mean that the Provent circuit will not flow gas from the cam covers to the intake manifold but that the scavenge pump will pull a large vacuum to whatever port in the intake manifold that the Provent gas exit is hooked up. This vacuum may then spread to the vacuum signal lines and impact, among other things, the fuel pressure regulators vacuum controlled set point.
Any thoughts, anyone?
With that explanation and keeping in mind that I've used my imagination to fill in a ton of blanks, here's what I came up with:
Attachment 687947
Since this is just a figment of my imagination, I will call the above-described system the "prankcase" evacuation system to differentiate it from anything that Greg may have actually installed on Rob's car.
Greg or Rob may
- choose to confirm that this prankcase system describes their system,
- may choose to deny that it describes their system with an explanation of what parts I just imagined,
- may choose to just deny that it describes their system without any explanation,
- or may choose to simply ignore this post.
I am obviosuly fine with any of these options, since it's their proprietary system and they are not obligated to tell me or the world anything about it. Any comment from them would be just intellectual charity. I'll just proceed to comment on the prankcase system that I imagined regardless of all this.
First, the prankcase system has a four stage scavenge pump with a single exit manifold, manufactured by Bill Dailey. The exit manifold is plumbed back to the pan. The four pickups are at the corners of the heads. The "secret sauce" parts under the valve cover scavenge near the corner head drains. In addition, the prankcase system has one of the valve covers hooked up to the oil filler neck and the other valve cover hooked up to the port between the knock sensors. The two remaining valve cover ports are hooked into the Provent via a T-fitting. The Provent drains oil to a T-fitting which is connected to one of the pump scavenge lines coming from the cam covers and going to the pump suction side. The Provent gas extraction port is connected to the intake manifold. The intent of the system is to use a pump to remove oil from the heads and return it to the sump.
Is everyone following?
Here's my mini-design review.
Positives:
+ I like the idea of venting the block from the middle of the valley. This should help reduce the need for the crankcase pulses to communicate thru the heads via the head drains.
+ I like the use of Provent as part of the system to reduce oil ingestion.
+ I like the fact that the pump outlet doesn't drain to valve cover or the oil filler neck but instead drains directly to the sump.
Negatives:
- The prankcase system scavenges the head oil drains from the top. In my opinion, it would be more effective to scavenge those from the other end of the drain channels, that is near the bottom of the block. This would avoid the active scavenge system actually pulling oil up into the heads that would've otherwise stayed in the crankcase.
- Mechanical scavenge pumps often scavenge a lot of gas as well as a lot of oil. It would be better to run an air-oil separator between the pump outlet and the sump.
- The prankcase system uses a T-fitting on one of the scavenge lines from the heads and connects that to the Provent. This has two undesirable effects. Since oil is heavier than gas, this pump stage scavenges gas only when either the Provent or the head pickup see gas. It scavenges oil only when both the Provent and the cam cover pickup see oil.
- The second undesirable effect of the scavenge line T-fitting is that the scavenge pump can easily pull a large vacuum into the Provent. This will likely mean that the Provent circuit will not flow gas from the cam covers to the intake manifold but that the scavenge pump will pull a large vacuum to whatever port in the intake manifold that the Provent gas exit is hooked up. This vacuum may then spread to the vacuum signal lines and impact, among other things, the fuel pressure regulators vacuum controlled set point.
Any thoughts, anyone?
#152
Tuomo,
One comment that I have on your comments there (it has been awhile since I have read through the thread, and looked at the few pictures), Greg used a dailey engineering pump, therefor likely has an air oil separator built onto the back of the pump to help de-aerate the oil.
That said, if Greg has connected to the stock vent pieces on the valve covers, then there is tubing under the cover making it pickup the oil at a much lower point in the head.
I will stop there.
One comment that I have on your comments there (it has been awhile since I have read through the thread, and looked at the few pictures), Greg used a dailey engineering pump, therefor likely has an air oil separator built onto the back of the pump to help de-aerate the oil.
That said, if Greg has connected to the stock vent pieces on the valve covers, then there is tubing under the cover making it pickup the oil at a much lower point in the head.
I will stop there.
#153
Supercharged
Rennlist Member
Rennlist Member
Joined: May 2002
Posts: 18,925
Likes: 66
From: Back in Michigan - Full time!
Risking reading too much into the tea leaves, I spent some time last night trying to reverse engineer the "active scavenge" system that Greg has advocated as the "racing" cure of the 928 oiling problems. I used the internet as the source, mainly photos by Rob and the various written comments posted by multiple people here on the RL. Of course, much of the system is proprietary and not disclosed, so I had to rely on my imagination heavily. Therefore, what I ended up as a result may or may not resemble what Greg installed on Rob's car.
With that explanation and keeping in mind that I've used my imagination to fill in a ton of blanks, here's what I came up with:
Attachment 687947
Since this is just a figment of my imagination, I will call the above-described system the "prankcase" evacuation system to differentiate it from anything that Greg may have actually installed on Rob's car.
Greg or Rob may
- choose to confirm that this prankcase system describes their system,
- may choose to deny that it describes their system with an explanation of what parts I just imagined,
- may choose to just deny that it describes their system without any explanation,
- or may choose to simply ignore this post.
I am obviosuly fine with any of these options, since it's their proprietary system and they are not obligated to tell me or the world anything about it. Any comment from them would be just intellectual charity. I'll just proceed to comment on the prankcase system that I imagined regardless of all this.
First, the prankcase system has a four stage scavenge pump with a single exit manifold, manufactured by Bill Dailey. The exit manifold is plumbed back to the pan. The four pickups are at the corners of the heads. The "secret sauce" parts under the valve cover scavenge near the corner head drains. In addition, the prankcase system has one of the valve covers hooked up to the oil filler neck and the other valve cover hooked up to the port between the knock sensors. The two remaining valve cover ports are hooked into the Provent via a T-fitting. The Provent drains oil to a T-fitting which is connected to one of the pump scavenge lines coming from the cam covers and going to the pump suction side. The Provent gas extraction port is connected to the intake manifold. The intent of the system is to use a pump to remove oil from the heads and return it to the sump.
Is everyone following?
Here's my mini-design review.
Positives:
+ I like the idea of venting the block from the middle of the valley. This should help reduce the need for the crankcase pulses to communicate thru the heads via the head drains.
+ I like the use of Provent as part of the system to reduce oil ingestion.
+ I like the fact that the pump outlet doesn't drain to valve cover or the oil filler neck but instead drains directly to the sump.
Negatives:
- The prankcase system scavenges the head oil drains from the top. In my opinion, it would be more effective to scavenge those from the other end of the drain channels, that is near the bottom of the block. This would avoid the active scavenge system actually pulling oil up into the heads that would've otherwise stayed in the crankcase.
- Mechanical scavenge pumps often scavenge a lot of gas as well as a lot of oil. It would be better to run an air-oil separator between the pump outlet and the sump.
- The prankcase system uses a T-fitting on one of the scavenge lines from the heads and connects that to the Provent. This has two undesirable effects. Since oil is heavier than gas, this pump stage scavenges gas only when either the Provent or the head pickup see gas. It scavenges oil only when both the Provent and the cam cover pickup see oil.
- The second undesirable effect of the scavenge line T-fitting is that the scavenge pump can easily pull a large vacuum into the Provent. This will likely mean that the Provent circuit will not flow gas from the cam covers to the intake manifold but that the scavenge pump will pull a large vacuum to whatever port in the intake manifold that the Provent gas exit is hooked up. This vacuum may then spread to the vacuum signal lines and impact, among other things, the fuel pressure regulators vacuum controlled set point.
Any thoughts, anyone?
With that explanation and keeping in mind that I've used my imagination to fill in a ton of blanks, here's what I came up with:
Attachment 687947
Since this is just a figment of my imagination, I will call the above-described system the "prankcase" evacuation system to differentiate it from anything that Greg may have actually installed on Rob's car.
Greg or Rob may
- choose to confirm that this prankcase system describes their system,
- may choose to deny that it describes their system with an explanation of what parts I just imagined,
- may choose to just deny that it describes their system without any explanation,
- or may choose to simply ignore this post.
I am obviosuly fine with any of these options, since it's their proprietary system and they are not obligated to tell me or the world anything about it. Any comment from them would be just intellectual charity. I'll just proceed to comment on the prankcase system that I imagined regardless of all this.
First, the prankcase system has a four stage scavenge pump with a single exit manifold, manufactured by Bill Dailey. The exit manifold is plumbed back to the pan. The four pickups are at the corners of the heads. The "secret sauce" parts under the valve cover scavenge near the corner head drains. In addition, the prankcase system has one of the valve covers hooked up to the oil filler neck and the other valve cover hooked up to the port between the knock sensors. The two remaining valve cover ports are hooked into the Provent via a T-fitting. The Provent drains oil to a T-fitting which is connected to one of the pump scavenge lines coming from the cam covers and going to the pump suction side. The Provent gas extraction port is connected to the intake manifold. The intent of the system is to use a pump to remove oil from the heads and return it to the sump.
Is everyone following?
Here's my mini-design review.
Positives:
+ I like the idea of venting the block from the middle of the valley. This should help reduce the need for the crankcase pulses to communicate thru the heads via the head drains.
+ I like the use of Provent as part of the system to reduce oil ingestion.
+ I like the fact that the pump outlet doesn't drain to valve cover or the oil filler neck but instead drains directly to the sump.
Negatives:
- The prankcase system scavenges the head oil drains from the top. In my opinion, it would be more effective to scavenge those from the other end of the drain channels, that is near the bottom of the block. This would avoid the active scavenge system actually pulling oil up into the heads that would've otherwise stayed in the crankcase.
- Mechanical scavenge pumps often scavenge a lot of gas as well as a lot of oil. It would be better to run an air-oil separator between the pump outlet and the sump.
- The prankcase system uses a T-fitting on one of the scavenge lines from the heads and connects that to the Provent. This has two undesirable effects. Since oil is heavier than gas, this pump stage scavenges gas only when either the Provent or the head pickup see gas. It scavenges oil only when both the Provent and the cam cover pickup see oil.
- The second undesirable effect of the scavenge line T-fitting is that the scavenge pump can easily pull a large vacuum into the Provent. This will likely mean that the Provent circuit will not flow gas from the cam covers to the intake manifold but that the scavenge pump will pull a large vacuum to whatever port in the intake manifold that the Provent gas exit is hooked up. This vacuum may then spread to the vacuum signal lines and impact, among other things, the fuel pressure regulators vacuum controlled set point.
Any thoughts, anyone?
The more I think about this issue the more I am beginning to believe that the root cause of these issues lies elsewhere. That's not to say this isn't a noble endeavor.
#154
Interesting that the pump can have a de-aeration feature - that can help understand Greg's report that the Provents are almost unneeded. Though as noted it suggests needing to scavenge other locations than just the heads.
Given that and the 4 'corner' head pick-ups - I also wondered about how the scavenging on a given pump port manages if it has more than one pick-up - both must be covered? - longitudinal/lateral accelerations may preclude that for a while..?
Alan
Last edited by Alan; 12-15-2012 at 02:41 PM.
#155
I havent taken my car apart to see the actual internal work. but I know greg spent gobs of time just figuring the right configuration for the intra head scavenging.....then there is the crankcase ventilation that he worked eons on.....
why so much crankcase pressure that seems to cause all this....is it ring and piston skirt design. does the nikasil bores help with diminishing crankcase pressure....why why why....as AO has stated ping, predetonation causes blow by to occur but in a new finely tuned engine shouldn't blow by be minimal or is blow by just normal....
I do seem to remember looking under my dads 49 dodge pickup and seeing fumes vented to atmosphere that was crankcase ventilation so I guess that answers my question...it always existss....huh
andy
why so much crankcase pressure that seems to cause all this....is it ring and piston skirt design. does the nikasil bores help with diminishing crankcase pressure....why why why....as AO has stated ping, predetonation causes blow by to occur but in a new finely tuned engine shouldn't blow by be minimal or is blow by just normal....
I do seem to remember looking under my dads 49 dodge pickup and seeing fumes vented to atmosphere that was crankcase ventilation so I guess that answers my question...it always existss....huh
andy
#156
Rennlist Member
Joined: Feb 2011
Posts: 2,255
Likes: 531
From: Mostly in my workshop located in Sweden.
Here you have a little more interesting reading to do. Check out posts 9, 14, 84, 89, 91, 94, 102, 119, 130 in particular.
https://rennlist.com/forums/924-931-...ng-fail-9.html
Ake
https://rennlist.com/forums/924-931-...ng-fail-9.html
Ake
#157
It'll be even more fun if you play! ;-)
Based on the pictures, I don't think Rob's car has the pump model which has the air oil-separator built in. In fact, I think (but do not know) that a four-stage pump with the air-oil separator wouldn't physically fit in that space, the separator element is long.
This is not my system, it's my "prankcase" reverse engineering effort of someone else's system with incomplete information. Quite possibly it's nothing like any system that is actually running anywhere. Also for the record, I had one of those expensive Dailey four-stage pumps, I would most assuredly not hook it up the like the "prankcase" system that I just drew -- I would put that pump to a more productive use.
If oil and air get pushed out from the crankcase into the heads you are by definition not adequately relieving crankcase pressure.
Any point you scavenge from the crankcase or the heads will pick up some air and some oil. The difference is in proportions of the two. The top of the crankcase, oil filler neck and the knock sensor ports, are probably points that would give you mostly air and only some oil. That's a guess.
Of course it's not treating the root cause. Personally, I think all these active scavenging and ventilation Rube Goldberg's machines are like treating diarrhea with a diaper. (I guess dry sump would be the colostomy bag in that analogy.) While it's usually better than soling your pants, the solution is far from ideal.
The root causes for oil blowing in the heads can be many. Speaking generally and not about anybody's engine specifically, a partial list of the reasons is the following:
- Someone put in really big cams with hydraulic lifters and forgot to check whether the oil pressure hole gets too close to the lifter edge
- The valve/orifice regulating the oil flow to the heads is incorrectly sized
- The crankshaft and piston movement create pressure zones that push oil and gas up the drain holes to the heads
- There's excessive blowby pressurizing the crankcase, because of poorly bedded rings, excessive oil on the bore walls, or too wide piston rings for the stroke and rpm.
Etc.
Of course, one is better off treating these causes and not the symptoms.
There's one further issue that one should keep in mind. Not everyone's engine fills up the heads with oil. My car doesn't spray oil out of the cam cover ports, and I've spent a lot of time with it on a (chassis) dyno. The Provent is quite dry. FredR's doesn't either. jorj7's heads don't fill with oil. Etc. In fact, many 78.9mm stroke engines with good ring seal and large enough hose ventilating the oil filler neck appear to be doing just fine. To the extent there's trouble, it coincides by the ring flutter starting.
I mostly agree. Pulling anything out of the heads, be that air or oil, is in my opinion a band-aid solution that makes the original problem worse by lowering the pressure in the cam cover. Anything that can be done to create a negative pressure differential between the crankcase (lower pressure) and the cam covers (higher pressure) helps, and anything that does the opposite hurts.
Where I disagree somewhat is that the parts inside the engine spin so fast that one can't assume that pressures equate. Instead, there can be zones with persistently different pressures.
When you actively scavenge from any point inside the engine, you ideally want to run the scavenged mixture thru an air-oil separator. If there's an active air-oil separator (I don't think Rob's has one) it runs automatically off the scavenge stage output in Dailey's pumps. If there's a Provent and if the scavenged fluid is mostly air, the scavenge pump output can (should?) be hooked to the Provent. The "prankcase system" uses the Provent in a way that doesn't fully use its air-oil separation capabilities.
What really makes no sense is scavenging the heads actively, then _not_ separating air and oil, and finally using the pump output of oil-air mixture to repressurize the crankcase. Think about it. You are trying to evacuate the crankcase and prevent oil from raising to the heads. Pulling a huge amount of air from the heads and then using it to pressurize the crankcase amounts to maximizing the oil flow up the drain channels to the heads. It's like pressure feeding the head with oil and air thru the drains.
Trying to scavenge more than one point with a single pump stage would be really dumb. Really dumb. That's why I drew the "secret sauce" pickups that are invisible in the photos to be single point pickups. I assumed that of course they would only pick up at a single point.
Every time I see a system described that tries to scavenge more than one point with a single stage I lose a little bit of my faith in the humanity. The internet forums are full of that kinds of plans and diagrams. For one to do that, one would have to BOTH have slept thru the high-school physics classes AND never tried to suck a milkshake with a straw that has a hole in it...
I don't think that blowby causes detonation or detonation causes blowby in a meaningful way. There's minor effects of knock retard on the combustion chamber to crankcase pressure differential, and of course long-term wear effects. But mostly it's just that blowby and detonation are both caused by too much oil on the cylinder bore walls overwhelming the oil control capabilities of the ring stock. That's my opinion anyway.
---
I think that this thread has helped clarify my thinking on this crankcase evacuation and oil drainage business. I think it's both fun and useful to try to think thru how actual and hypothetical systems flow.
One comment that I have on your comments there (it has been awhile since I have read through the thread, and looked at the few pictures), Greg used a dailey engineering pump, therefor likely has an air oil separator built onto the back of the pump to help de-aerate the oil.
If oil and air get pushed out from the crankcase into the heads you are by definition not adequately relieving crankcase pressure.
Any point you scavenge from the crankcase or the heads will pick up some air and some oil. The difference is in proportions of the two. The top of the crankcase, oil filler neck and the knock sensor ports, are probably points that would give you mostly air and only some oil. That's a guess.
The root causes for oil blowing in the heads can be many. Speaking generally and not about anybody's engine specifically, a partial list of the reasons is the following:
- Someone put in really big cams with hydraulic lifters and forgot to check whether the oil pressure hole gets too close to the lifter edge
- The valve/orifice regulating the oil flow to the heads is incorrectly sized
- The crankshaft and piston movement create pressure zones that push oil and gas up the drain holes to the heads
- There's excessive blowby pressurizing the crankcase, because of poorly bedded rings, excessive oil on the bore walls, or too wide piston rings for the stroke and rpm.
Etc.
Of course, one is better off treating these causes and not the symptoms.
There's one further issue that one should keep in mind. Not everyone's engine fills up the heads with oil. My car doesn't spray oil out of the cam cover ports, and I've spent a lot of time with it on a (chassis) dyno. The Provent is quite dry. FredR's doesn't either. jorj7's heads don't fill with oil. Etc. In fact, many 78.9mm stroke engines with good ring seal and large enough hose ventilating the oil filler neck appear to be doing just fine. To the extent there's trouble, it coincides by the ring flutter starting.
The Oil filler crank port alone is huge - pretty difficult to clog it with oil - however how useful that is depends on what happens in and above the 'filler'. The heads and crank will always equalize through the head drain ports. In fact when venting from the cam covers there will be some constant flow up the head drains - its the only way to get there (unless you are oil).
Where I disagree somewhat is that the parts inside the engine spin so fast that one can't assume that pressures equate. Instead, there can be zones with persistently different pressures.
What really makes no sense is scavenging the heads actively, then _not_ separating air and oil, and finally using the pump output of oil-air mixture to repressurize the crankcase. Think about it. You are trying to evacuate the crankcase and prevent oil from raising to the heads. Pulling a huge amount of air from the heads and then using it to pressurize the crankcase amounts to maximizing the oil flow up the drain channels to the heads. It's like pressure feeding the head with oil and air thru the drains.
Every time I see a system described that tries to scavenge more than one point with a single stage I lose a little bit of my faith in the humanity. The internet forums are full of that kinds of plans and diagrams. For one to do that, one would have to BOTH have slept thru the high-school physics classes AND never tried to suck a milkshake with a straw that has a hole in it...
I havent taken my car apart to see the actual internal work. but I know greg spent gobs of time just figuring the right configuration for the intra head scavenging.....then there is the crankcase ventilation that he worked eons on..... why so much crankcase pressure that seems to cause all this....is it ring and piston skirt design. does the nikasil bores help with diminishing crankcase pressure....why why why....as AO has stated ping, predetonation causes blow by to occur but in a new finely tuned engine shouldn't blow by be minimal or is blow by just normal.... I do seem to remember looking under my dads 49 dodge pickup and seeing fumes vented to atmosphere that was crankcase ventilation so I guess that answers my question...it always existss....huh
---
I think that this thread has helped clarify my thinking on this crankcase evacuation and oil drainage business. I think it's both fun and useful to try to think thru how actual and hypothetical systems flow.
#158
Here you have a little more interesting reading to do. Check out posts 9, 14, 84, 89, 91, 94, 102, 119, 130 in particular.
https://rennlist.com/forums/924-931-...ng-fail-9.html Ake
https://rennlist.com/forums/924-931-...ng-fail-9.html Ake
My main comment on that thread is that of course the racing oils are designed to lubricate the best at something like 285 F temperature. And of course the oil that you feed to the engine needs to be about 235 F to get there. That's because the oil inside the bearing heats up by about 50 F. Some confusion eliminated, hopefully.
This is not a pure guess, one of the big three car companies instrumented the living daylight out of one engine and measured the oil temperature at every point. Whatever temperature you feed in to the block is about 50 F lower than the temperature at which the oil actually operates under huge pressure inside the journal bearings. I think the research is out on the web, google it.
#159
However maybe I should have said something more like "tends to equalize via the open head drain ports" - any sustained net difference between these areas will drive flow through those ports. If a dynamic pressure difference doesn't drive flow in the drains for temporal reasons I don't think it matters much and we can probably just ignore it...
It certainly seems to me that any significant venting from the cam covers must encourage less net oil flow down the head drains - can't be good...
Alan
#160
I mostly agree. Pulling anything out of the heads, be that air or oil, is in my opinion a band-aid solution that makes the original problem worse by lowering the pressure in the cam cover. Anything that can be done to create a negative pressure differential between the crankcase (lower pressure) and the cam covers (higher pressure) helps, and anything that does the opposite hurts.
I'm suddenly wondering if its possible to model the system as a fluid dynamics problem - do we have any chemical engineers here? Maybe drawing up the whole system as a pipework diagram - with pipes/orifices in between all the volumes representing the CSA/diameter of the various ventilation points in the system (stock breather ports in the cam covers, oil filler neck, possibly the valley port, holes between cylinders in the crankcase, each drain hole from the heads), and take the system input as the blow-by gasses (around rings and valves). It should be possible to model the pressures at each orifice at various states, and thus have at least a theoretical idea of where the static pressures are high or low, and which way crankcase gases flow.
My gut feel is that a good setup would be:
1. Vacuum pump like Colin's relatively inexpensive one (in this post here), (or even the bigger 33cfm version?).
2. Suck vacuum (oil mist) from the oil filler neck and an unused valley plug
3. Push oil mist (pump output) into the front breather ports on the cam covers - this creates two flow loops which run from the heads *out* through the front drains and encourage oil flow out of the heads. Use the stock extenders (which are usually found on the rear-right breather port on an S4), or if they won't fit, make one which will, and direct it towards a drain.
4. Vent the rear ports of the cam covers (with no extenders), where there will be a higher static pressure (out of the path of the flow loops set up by step 3.) to a provent or other air/oil separator, using the less-restrictive stock elbows.
5. Drain the provent back to the crankcase through the dipstick, or bolted block-off plate (up to mid-87 pans), or a new port like in GB/Robs photos.
6. Plumb the "clean air" side of the provent to the intake.
As I see it, this has the following advantages:
a) Higher static pressure to the provent from the rear of the heads encourages flow of air to the intake - minimising net crankcase pressure for a given input.
b) Constant vacuuming of the windage cloud that forms around the crank in the crankcase - its in the flow path from the drains to the vacuum pump
c) Gas flow encourages draining of oil to the crankcase - formation of oil "plugs" will be impeded as gas flow will break up the plugs. Flowrate is rpm dependent so faster rpm's = more "encouragement".
d) Could be installed without removing heads/engine
e) cheaper than the 4-stage pump setup
It has these disadvantages:
i) Doesn't address oil thrown by the crank up the right-side drains (Mike S has modified his engine to reduce this by extending the drains)
ii) Isn't actively pumping gases out of the engine
iii) Doesn't address oil flow into the heads from the oiling system
I do think there's a place for 4-stage scavenging pumps with air/oil separators - whether from Dailey or Auto Verdi (talked about by Greg Gray), in making properly dry-sumped 928's, like the photos from our German friends posted earlier in this thread.
Of course, I'm not an engineer. I planned on being one, but changed plans and did computing instead So this is all based on conjecture on my part, and could be wrong.
#161
It'll be even more fun if you play! ;-)
Sometimes it is difficult to tell how much pictures reveal [when you really don't feel like teaching the entire world what you just did....for free...for 3 months of your life. (Worth noting, right here, is that Andy paid zero dollars for the developmental work, but paid only for the final pieces....this was completely my own developmental work.) I was very careful about what pictures got published...and some pictures were taken and inserted during steps that didn't necessary work...intentionally. Turns out that Rob Edwards had a much better insight about the pictures, than I did. "You have to be realistic, Greg, you could provide people with exact detailed pictures of what was going on, from the outside, and they wouldn't have a clue, until they saw what was on the inside."
I know what I tried. I know what worked. I know what didn't work. There were many iterations. By the time I was done, I completely understood what Porsche had been doing and why. I understood why they couldn't "fix" the problem, without a major redesign and large investment. I understood what they did on their "Marine" engine....and why. I thought that I understood all the reasons for rod bearing failures, before I undertook this project. I actually understood only the results of the failures, not all the root causes. In short, I finally "got" it.
This knowledge then allowed me to build a "non-active pump" system. This took another 3 months of "free" effort. This was a major redesign and has very complex changes in many different places. I also have no desire to educate everyone about this system.
What few know here, and has not been mentioned, is that either system comes complete with an informal non-disclosure agreement. You are requested, as part of the purchase, to not publish pictures of the installation or the instructions. You are requested to not forward the instructions. I've got no reason to give this knowledge away. It was very difficult to figure out (Porsche couldn't/didn't do it, nor has anyone else done it) and I have absolutely no reason to give this knowledge to anyone.
Based on the pictures, I don't think Rob's car has the pump model which has the air oil-separator built in. In fact, I think (but do not know) that a four-stage pump with the air-oil separator wouldn't physically fit in that space, the separator element is long.
Look at the pictures of Rob's pump, running on the dyno and you will be really confused!
This is not my system, it's my "prankcase" reverse engineering effort of someone else's system with incomplete information. Quite possibly it's nothing like any system that is actually running anywhere. Also for the record, I had one of those expensive Dailey four-stage pumps, I would most assuredly not hook it up the like the "prankcase" system that I just drew -- I would put that pump to a more productive use.
If oil and air get pushed out from the crankcase into the heads you are by definition not adequately relieving crankcase pressure. Really? Think about that statement, some. As long as the crankcase and heads are connected by a clear airpath (not blocked by oil) the pressure is by definition, is the same, in those two "vessels'.
Any point you scavenge from the crankcase or the heads will pick up some air and some oil. The difference is in proportions of the two. The top of the crankcase, oil filler neck and the knock sensor ports, are probably points that would give you mostly air and only some oil. That's a guess. And not accurate. Remove an oil filler 'neck" and look down.
Of course it's not treating the root cause. Personally, I think all these active scavenging and ventilation Rube Goldberg's machines are like treating diarrhea with a diaper. (I guess dry sump would be the colostomy bag in that analogy.) While it's usually better than soling your pants, the solution is far from ideal. Not sure what you are saying here. Every engine has windage, scavenging, and ventilation "issues". It comes from the requirements of lubrication. Every engine has to address these issues. The solutions for the 928 engine, simply stated, were not adequate.
The root causes for oil blowing in the heads can be many. Speaking generally and not about anybody's engine specifically, a partial list of the reasons is the following:
- Someone put in really big cams with hydraulic lifters and forgot to check whether the oil pressure hole gets too close to the lifter edge
- The valve/orifice regulating the oil flow to the heads is incorrectly sized
- The crankshaft and piston movement create pressure zones that push oil and gas up the drain holes to the heads
- There's excessive blowby pressurizing the crankcase, because of poorly bedded rings, excessive oil on the bore walls, or too wide piston rings for the stroke and rpm.
Etc.
More of "etc" than any of the above? Seriously....Throwing out a bunch of basic "Engine 101" ideas and calling them the "root causes" isn't very enlightening, to the entire discussion. Makes me think about "moving you over" to the list of the people that think rods don't need to be centered, under the pistons. And those people are "really dumb".
Of course, one is better off treating these causes and not the symptoms.
There's one further issue that one should keep in mind. Not everyone's engine fills up the heads with oil. My car doesn't spray oil out of the cam cover ports, and I've spent a lot of time with it on a (chassis) dyno. The Provent is quite dry. FredR's doesn't either. jorj7's heads don't fill with oil. Etc. In fact, many 78.9mm stroke engines with good ring seal and large enough hose ventilating the oil filler neck appear to be doing just fine. To the extent there's trouble, it coincides by the ring flutter starting.
Therefore, you do not have a problem and you are wasting your time thinking about all of this stuff?
I mostly agree. Pulling anything out of the heads, be that air or oil, is in my opinion a band-aid solution that makes the original problem worse by lowering the pressure in the cam cover. Anything that can be done to create a negative pressure differential between the crankcase (lower pressure) and the cam covers (higher pressure) helps, and anything that does the opposite hurts.
See above. As long as the two "vessels" remain connected by a free air path, the pressure in the two remains the same. The "problem" with the "stock" design is that the drains quickly get overwhelmed and the pressure in the crankcase builds, until there is a huge "burp". Once that burp occurs, oil is pushed up and out of the crankcase, through the oil return holes. At that point, there is a lot of oil in the heads...and being pushed into the intake system (on a stock vehicle.) Take the time to carefully study all the iterations of the stock ventilation systems (as I had to do). Stop and consider what has to happen, for oil to be ejected from the rear right valve cover vent and make it into the intake system....and then sit there and tell me that there is no problem!
Where I disagree somewhat is that the parts inside the engine spin so fast that one can't assume that pressures equate. Instead, there can be zones with persistently different pressures. "Local pressure" differentials equalize very quickly, in an open vessel. Try blowing a huge volume of air, with lots of pressure into an empty tank, from one end. The pressure differential from one end to the other end of that vessel is extremely low. Those molecules move really, really quick.
When you actively scavenge from any point inside the engine, you ideally want to run the scavenged mixture thru an air-oil separator. If there's an active air-oil separator (I don't think Rob's has one) it runs automatically off the scavenge stage output in Dailey's pumps. If there's a Provent and if the scavenged fluid is mostly air, the scavenge pump output can (should?) be hooked to the Provent. The "prankcase system" uses the Provent in a way that doesn't fully use its air-oil separation capabilities.
What really makes no sense is scavenging the heads actively, then _not_ separating air and oil, and finally using the pump output of oil-air mixture to repressurize the crankcase. Think about it. You are trying to evacuate the crankcase and prevent oil from raising to the heads. Pulling a huge amount of air from the heads and then using it to pressurize the crankcase amounts to maximizing the oil flow up the drain channels to the heads. It's like pressure feeding the head with oil and air thru the drains. See above. You have completely missed my main reason to remove the oil from the heads.
Trying to scavenge more than one point with a single pump stage would be really dumb. Really dumb. That's why I drew the "secret sauce" pickups that are invisible in the photos to be single point pickups. I assumed that of course they would only pick up at a single point.
The truth is finally out! I'm dumb. Really dumb. Really, really dumb. But I've solved the ventilation problems, with 928 engines, with two separate systems....something that no one has been able to do....even Porsche....for over 30 years! I guess I'd rather be lucky than smart? Just a quick point.....without saying anything else. The two heads fill with oil at almost the exact same rate!
Every time I see a system described that tries to scavenge more than one point with a single stage I lose a little bit of my faith in the humanity. The internet forums are full of that kinds of plans and diagrams. For one to do that, one would have to BOTH have slept thru the high-school physics classes AND never tried to suck a milkshake with a straw that has a hole in it...
I don't think that blowby causes detonation (Do you have any idea of what a tiny bit of oil does to the effective octane of the fuel? Now push a huge volume of oil into the combustion chambers...like the GTS vehicles do....and figure out the effect!) or detonation causes blowby in a meaningful way. There's minor effects of knock retard on the combustion chamber to crankcase pressure differential, and of course long-term wear effects. But mostly it's just that blowby and detonation are both caused by too much oil on the cylinder bore walls overwhelming the oil control capabilities of the ring stock. That's my opinion anyway.
---
I think that this thread has helped clarify my thinking on this crankcase evacuation and oil drainage business. I think it's both fun and useful to try to think thru how actual and hypothetical systems flow.
Sometimes it is difficult to tell how much pictures reveal [when you really don't feel like teaching the entire world what you just did....for free...for 3 months of your life. (Worth noting, right here, is that Andy paid zero dollars for the developmental work, but paid only for the final pieces....this was completely my own developmental work.) I was very careful about what pictures got published...and some pictures were taken and inserted during steps that didn't necessary work...intentionally. Turns out that Rob Edwards had a much better insight about the pictures, than I did. "You have to be realistic, Greg, you could provide people with exact detailed pictures of what was going on, from the outside, and they wouldn't have a clue, until they saw what was on the inside."
I know what I tried. I know what worked. I know what didn't work. There were many iterations. By the time I was done, I completely understood what Porsche had been doing and why. I understood why they couldn't "fix" the problem, without a major redesign and large investment. I understood what they did on their "Marine" engine....and why. I thought that I understood all the reasons for rod bearing failures, before I undertook this project. I actually understood only the results of the failures, not all the root causes. In short, I finally "got" it.
This knowledge then allowed me to build a "non-active pump" system. This took another 3 months of "free" effort. This was a major redesign and has very complex changes in many different places. I also have no desire to educate everyone about this system.
What few know here, and has not been mentioned, is that either system comes complete with an informal non-disclosure agreement. You are requested, as part of the purchase, to not publish pictures of the installation or the instructions. You are requested to not forward the instructions. I've got no reason to give this knowledge away. It was very difficult to figure out (Porsche couldn't/didn't do it, nor has anyone else done it) and I have absolutely no reason to give this knowledge to anyone.
Based on the pictures, I don't think Rob's car has the pump model which has the air oil-separator built in. In fact, I think (but do not know) that a four-stage pump with the air-oil separator wouldn't physically fit in that space, the separator element is long.
Look at the pictures of Rob's pump, running on the dyno and you will be really confused!
This is not my system, it's my "prankcase" reverse engineering effort of someone else's system with incomplete information. Quite possibly it's nothing like any system that is actually running anywhere. Also for the record, I had one of those expensive Dailey four-stage pumps, I would most assuredly not hook it up the like the "prankcase" system that I just drew -- I would put that pump to a more productive use.
If oil and air get pushed out from the crankcase into the heads you are by definition not adequately relieving crankcase pressure. Really? Think about that statement, some. As long as the crankcase and heads are connected by a clear airpath (not blocked by oil) the pressure is by definition, is the same, in those two "vessels'.
Any point you scavenge from the crankcase or the heads will pick up some air and some oil. The difference is in proportions of the two. The top of the crankcase, oil filler neck and the knock sensor ports, are probably points that would give you mostly air and only some oil. That's a guess. And not accurate. Remove an oil filler 'neck" and look down.
Of course it's not treating the root cause. Personally, I think all these active scavenging and ventilation Rube Goldberg's machines are like treating diarrhea with a diaper. (I guess dry sump would be the colostomy bag in that analogy.) While it's usually better than soling your pants, the solution is far from ideal. Not sure what you are saying here. Every engine has windage, scavenging, and ventilation "issues". It comes from the requirements of lubrication. Every engine has to address these issues. The solutions for the 928 engine, simply stated, were not adequate.
The root causes for oil blowing in the heads can be many. Speaking generally and not about anybody's engine specifically, a partial list of the reasons is the following:
- Someone put in really big cams with hydraulic lifters and forgot to check whether the oil pressure hole gets too close to the lifter edge
- The valve/orifice regulating the oil flow to the heads is incorrectly sized
- The crankshaft and piston movement create pressure zones that push oil and gas up the drain holes to the heads
- There's excessive blowby pressurizing the crankcase, because of poorly bedded rings, excessive oil on the bore walls, or too wide piston rings for the stroke and rpm.
Etc.
More of "etc" than any of the above? Seriously....Throwing out a bunch of basic "Engine 101" ideas and calling them the "root causes" isn't very enlightening, to the entire discussion. Makes me think about "moving you over" to the list of the people that think rods don't need to be centered, under the pistons. And those people are "really dumb".
Of course, one is better off treating these causes and not the symptoms.
There's one further issue that one should keep in mind. Not everyone's engine fills up the heads with oil. My car doesn't spray oil out of the cam cover ports, and I've spent a lot of time with it on a (chassis) dyno. The Provent is quite dry. FredR's doesn't either. jorj7's heads don't fill with oil. Etc. In fact, many 78.9mm stroke engines with good ring seal and large enough hose ventilating the oil filler neck appear to be doing just fine. To the extent there's trouble, it coincides by the ring flutter starting.
Therefore, you do not have a problem and you are wasting your time thinking about all of this stuff?
I mostly agree. Pulling anything out of the heads, be that air or oil, is in my opinion a band-aid solution that makes the original problem worse by lowering the pressure in the cam cover. Anything that can be done to create a negative pressure differential between the crankcase (lower pressure) and the cam covers (higher pressure) helps, and anything that does the opposite hurts.
See above. As long as the two "vessels" remain connected by a free air path, the pressure in the two remains the same. The "problem" with the "stock" design is that the drains quickly get overwhelmed and the pressure in the crankcase builds, until there is a huge "burp". Once that burp occurs, oil is pushed up and out of the crankcase, through the oil return holes. At that point, there is a lot of oil in the heads...and being pushed into the intake system (on a stock vehicle.) Take the time to carefully study all the iterations of the stock ventilation systems (as I had to do). Stop and consider what has to happen, for oil to be ejected from the rear right valve cover vent and make it into the intake system....and then sit there and tell me that there is no problem!
Where I disagree somewhat is that the parts inside the engine spin so fast that one can't assume that pressures equate. Instead, there can be zones with persistently different pressures. "Local pressure" differentials equalize very quickly, in an open vessel. Try blowing a huge volume of air, with lots of pressure into an empty tank, from one end. The pressure differential from one end to the other end of that vessel is extremely low. Those molecules move really, really quick.
When you actively scavenge from any point inside the engine, you ideally want to run the scavenged mixture thru an air-oil separator. If there's an active air-oil separator (I don't think Rob's has one) it runs automatically off the scavenge stage output in Dailey's pumps. If there's a Provent and if the scavenged fluid is mostly air, the scavenge pump output can (should?) be hooked to the Provent. The "prankcase system" uses the Provent in a way that doesn't fully use its air-oil separation capabilities.
What really makes no sense is scavenging the heads actively, then _not_ separating air and oil, and finally using the pump output of oil-air mixture to repressurize the crankcase. Think about it. You are trying to evacuate the crankcase and prevent oil from raising to the heads. Pulling a huge amount of air from the heads and then using it to pressurize the crankcase amounts to maximizing the oil flow up the drain channels to the heads. It's like pressure feeding the head with oil and air thru the drains. See above. You have completely missed my main reason to remove the oil from the heads.
Trying to scavenge more than one point with a single pump stage would be really dumb. Really dumb. That's why I drew the "secret sauce" pickups that are invisible in the photos to be single point pickups. I assumed that of course they would only pick up at a single point.
The truth is finally out! I'm dumb. Really dumb. Really, really dumb. But I've solved the ventilation problems, with 928 engines, with two separate systems....something that no one has been able to do....even Porsche....for over 30 years! I guess I'd rather be lucky than smart? Just a quick point.....without saying anything else. The two heads fill with oil at almost the exact same rate!
Every time I see a system described that tries to scavenge more than one point with a single stage I lose a little bit of my faith in the humanity. The internet forums are full of that kinds of plans and diagrams. For one to do that, one would have to BOTH have slept thru the high-school physics classes AND never tried to suck a milkshake with a straw that has a hole in it...
I don't think that blowby causes detonation (Do you have any idea of what a tiny bit of oil does to the effective octane of the fuel? Now push a huge volume of oil into the combustion chambers...like the GTS vehicles do....and figure out the effect!) or detonation causes blowby in a meaningful way. There's minor effects of knock retard on the combustion chamber to crankcase pressure differential, and of course long-term wear effects. But mostly it's just that blowby and detonation are both caused by too much oil on the cylinder bore walls overwhelming the oil control capabilities of the ring stock. That's my opinion anyway.
---
I think that this thread has helped clarify my thinking on this crankcase evacuation and oil drainage business. I think it's both fun and useful to try to think thru how actual and hypothetical systems flow.
And having looked carefully at what you are saying....I'm not convinced that you are trying to figure out what is "right" about this system (that you've never seen, used, or tested) as much as you are trying to figure out what is "wrong" with what I've done.
That, in itself, might be the most interesting part of this entire discussion, for me.
I don't do this stuff to make money. I could make more money doing oil changes for 9 months than sitting around pondering what I need to do to make a ventilation system work on an obscure engine on a very tiny little market segment.
I could/probably should have called Andy and said: "Sorry. Confirmed that these engines are going to blow up, when run at high rpms, for extended periods of time....just like the have been doing since the very beginning."
That's just not my style. I "undertook" the huge task of figuring out what was wrong and then designed and built pieces that solved the problems.....again, something that no one else has been able to do! And now, I "get" to listen to you tell me what is wrong with what I did? Are you ****ing serious?
I do this stuff because I like to think and I love to solve problems. When I'm done, I then fill a large box with "hand made jewelry" that cost me $4,000 worth of time to build and then send that box to people that are also trying to improve their "obscure engine", charging them less than $2,000.
You might be right, I might be "dumb. Really dumb".
Last edited by GregBBRD; 12-15-2012 at 07:59 PM.
#162
Yep - in fact they went as far as racing there very successfully in the VLN series with an 1980 Euro S (300bhp) as a base for their race car. The famous Brumos 928 that ran at Daytona had the lap record in the VLN for 2 yrs running. The other car, which Porsche prepped and helped with is currently maintained by Uwe...
#163
is there lots of problems with the factory oiling system....YES.....
However I think the single largest problem is aeration.....the OB pan is a excellent cure for this issue, as it de-aerates quite well......most hard driven 928's have started using the OB pan with excellent results.....over 100 hours on track on my old estate and over 12 on my current racer pulling 1.5+ G on slicks....
I also think the primary cause of crankcase pressure (on a well running engine..meaning rings are working well) is the crank whipping up the oil due to high oil level and its just too close to the spinning counterweights.....a 3/8th pan spacer improves this quite a bit...and increases total oil capacity by 1.4 qts...
The more mystery issues is the excessive oiling to the heads-cams which can cause starvation issues due to the heads being packed with oil in extened high load running.....Doc's scavenge system like on Robs GTS works very well to solve this with the added benefit of lower oil consumption....
Another problem related to crankcase pressures is oil getting injected into the intake...a typical smog issue on street cars......oil has no business anywhere near the intake....but is required on a street car...which is easily solved by blocking the intake feed lines and-or a proper provent setup....but these are complicated and pricey...catch cans work, but can fill up quickly and make a mess... I really like the factory 16V oil filler-separator on early cars...worlds better than the later setup that does nothing to separate or de-aerate the oil mist or reduce pressures....a simple vent and the 1" top filler port relieves most of the crankcase pressure.....
Everyone has a theory on how to improve the 928 oiling system......I tried a few things and know what works for me....the results speak for themselves.....in terms of who I trust.....I trust Doc Brown....why.....everything he builds WORKS & lives for a long time...
However I think the single largest problem is aeration.....the OB pan is a excellent cure for this issue, as it de-aerates quite well......most hard driven 928's have started using the OB pan with excellent results.....over 100 hours on track on my old estate and over 12 on my current racer pulling 1.5+ G on slicks....
I also think the primary cause of crankcase pressure (on a well running engine..meaning rings are working well) is the crank whipping up the oil due to high oil level and its just too close to the spinning counterweights.....a 3/8th pan spacer improves this quite a bit...and increases total oil capacity by 1.4 qts...
The more mystery issues is the excessive oiling to the heads-cams which can cause starvation issues due to the heads being packed with oil in extened high load running.....Doc's scavenge system like on Robs GTS works very well to solve this with the added benefit of lower oil consumption....
Another problem related to crankcase pressures is oil getting injected into the intake...a typical smog issue on street cars......oil has no business anywhere near the intake....but is required on a street car...which is easily solved by blocking the intake feed lines and-or a proper provent setup....but these are complicated and pricey...catch cans work, but can fill up quickly and make a mess... I really like the factory 16V oil filler-separator on early cars...worlds better than the later setup that does nothing to separate or de-aerate the oil mist or reduce pressures....a simple vent and the 1" top filler port relieves most of the crankcase pressure.....
Everyone has a theory on how to improve the 928 oiling system......I tried a few things and know what works for me....the results speak for themselves.....in terms of who I trust.....I trust Doc Brown....why.....everything he builds WORKS & lives for a long time...
#164
Originally Posted by ptuomov
If oil and air get pushed out from the crankcase into the heads you are by definition not adequately relieving crankcase pressure.
Originally Posted by ptuomov
Any point you scavenge from the crankcase or the heads will pick up some air and some oil. The difference is in proportions of the two. The top of the crankcase, oil filler neck and the knock sensor ports, are probably points that would give you mostly air and only some oil. That's a guess.
Originally Posted by ptuomov
Of course it's not treating the root cause. Personally, I think all these active scavenging and ventilation Rube Goldberg's machines are like treating diarrhea with a diaper. (I guess dry sump would be the colostomy bag in that analogy.) While it's usually better than soling your pants, the solution is far from ideal.
Seriously....Throwing out a bunch of basic "Engine 101" ideas and calling them the "root causes" isn't very enlightening, to the entire discussion. Makes me think about "moving you over" to the list of the people that think rods don't need to be centered, under the pistons. And those people are "really dumb".
What you think about me doesn't matter much to anyone. What I think about you matters equally little. However, our writings and behavior on this forum do lead the other readers and posters to form opinions about the both of us. I think that this matters to some extent, especially given that you don't want to describe in detail all of your solutions and you are therefore relying on your general credibility to sell your products.
I don't think that the blowby, ring flutter, and bore wall oil control are "a bunch of basic Engine 101 ideas." I think they are specific problems with the 928 S4 engine. I did the basic computations for the S4 by hand once to find the critical flutter rpm for the S4. I also use a simulator when working on my engine that not only estimates the ring flutter critical rpm but also tracks the flutter-induced blowby over the cycle. This gives and output that is a quantitative estimate of the blowby in each operating condition. Now, the simulator is not perfect and the company that sells the simulator also sells a blowby sensor that tracks the actual amount of blowby in the engine. I don't own that sensor, but I hope buy it some day.
As a side note, specifically about my turbocharged S4 engine, compensating the decline in the volumetric efficiency by increasing the boost has the positive side effect of moving the ring-flutter critical rpm to a much higher level.
Originally Posted by ptuomov
There's one further issue that one should keep in mind. Not everyone's engine fills up the heads with oil. My car doesn't spray oil out of the cam cover ports, and I've spent a lot of time with it on a (chassis) dyno. The Provent is quite dry. FredR's doesn't either. jorj7's heads don't fill with oil. Etc. In fact, many 78.9mm stroke engines with good ring seal and large enough hose ventilating the oil filler neck appear to be doing just fine. To the extent there's trouble, it coincides by the ring flutter starting.
Now, there's some method to my madness. Currently, I have an engien that works pretty well at the desired rpm range when it stands upright and is not subjected to acceleration forces. However, the engine would most likely not fare well on a track, with sticky tires. My goal is to first understand the 928 oiling system as well as possible and then design a solution to all the potential problems. Maybe I'll succeed, maybe I'll fail, but the fun to me is in the understanding and solving part.
Originally Posted by ptuomov
I mostly agree. Pulling anything out of the heads, be that air or oil, is in my opinion a band-aid solution that makes the original problem worse by lowering the pressure in the cam cover. Anything that can be done to create a negative pressure differential between the crankcase (lower pressure) and the cam covers (higher pressure) helps, and anything that does the opposite hurts.
Originally Posted by ptuomov
Where I disagree somewhat is that the parts inside the engine spin so fast that one can't assume that pressures equate. Instead, there can be zones with persistently different pressures.
Originally Posted by ptuomov
Trying to scavenge more than one point with a single pump stage would be really dumb. Really dumb. That's why I drew the "secret sauce" pickups that are invisible in the photos to be single point pickups. I assumed that of course they would only pick up at a single point.
I do however stand by my opinion that it's dumb to try to pick up oil with multiple pickups per scavenge pump stage from a system that has both air and oil. If any of the pickups catches air, one will just get air.
You are putting the "cart in front of the horse", in my opinion. Before I even started to make changes, I studied all the different iterations of the factory attempts at ventilation.....for months. When Andy's engine "ejected" oil at high rpms, I did nothing, but think about what had happened and why, for about 3 months. Until you have done this and understand why each one of these changes was done (there were many, many changes....some in "mid-year", without any change to the "PET" pieces), you really don't have a chance of figuring this all out.
And having looked carefully at what you are saying....I'm not convinced that you are trying to figure out what is "right" about this system (that you've never seen, used, or tested) as much as you are trying to figure out what is "wrong" with what I've done. That, in itself, might be the most interesting part of this entire discussion, for me.
I admit that I am quite annoyed about your marketing antics on this forum. I don't on an emotionally level accept attempts to sell a system without an explanation how it works. On a logical level, I do understand that proprietary information can't be published freely without it losing it's proprietary nature. In any case, I am trying to leave my emotions out of it and simply find out the truth about technical matters by debating other people here, including you.
As a separate matter, I think that intentionally misleading people reading this forum on a technical matter, something to which you admitted to earlier, is completely unacceptable from any perspective.
I could/probably should have called Andy and said: "Sorry. Confirmed that these engines are going to blow up, when run at high rpms, for extended periods of time....just like the have been doing since the very beginning." That's just not my style. I "undertook" the huge task of figuring out what was wrong and then designed and built pieces that solved the problems.....again, something that no one else has been able to do! And now, I "get" to listen to you tell me what is wrong with what I did? Are you ****ing serious?
Counterbalancing my views about your marketing antics, I do admire your dedication to your customers. We don't see many, in fact any, of your customers complaining here. That tells me something. However, let me also say that there may be some potential customers for you here that haven't experienced your dedication first hand and are put off by your marketing style to the point that they never become your customers and never experience being your customer.
#165
I admire your dedication to the 928 and your customers. However, I am disappointed by your admission that you are intentionally misleading the readers of this forum on a technical issue. You are writing about a system that you claim solves a problem and then in the posts that you and your customers together compose to this forum you intentionally, by your own admission, insert pictures of a system that is not what you are actually selling and that you think don't works. Do you understand what this does to your credibility as a source of technical information on this forum?
It is my understanding about fluid dynamics that fluid does not move without a pressure differential and a pressure differential doesn't exist without fluid movement. Because of this, I think that if oil and air flow from the crankcase from the heads, a pressure differential must exist. Given the velocities and the geometry, I don't think it's useful to think about the heads and the crankcase as a part of the same open vessel.
Whether or not it is accurate, it can't be verified by looking down the chimney of the running engine. You'll just see a bunch of oil churning, but you can't estimate the proportions of the two from that visual. Furthermore, the gas vent angle will materially influence what you pick up from that spot, because oil has much higher density than crankcase gasses. So what you see thru a plexiglass plate on the chimney will not tell you whether my guess is accurate or not.
Perhaps the analogy is not a good one. What I mean is that while every engine has some blowby, with a healthy level being in the neighborhood of 3% of the exhaust gas volume, unhealthy engines push much more blowby to the crankcase. While I don't know anything about your strokers, I firmly believe that the stock S4 engine blowby is normal until either of the two things happens. First, either so much oil gets thrown to the cylinder walls that the oil control is lost and the ring seal with it. Second, the rpm becomes high enough such that the rings "flutter", that is, the inertial forces on the piston rings overcome the pressure differential between the combustion chamber and the crankcase. In either of those cases, the blowby increases dramatically and all sorts of trouble starts. Attempting to relieve the symptoms with crankcase evacuation systems may mitigate the damage but will not address the underlying true causes of the problems.
I am trying to keep this completely technical as much as I can. However, I will, reluctantly, respond to ad hominem stuff in kind. Please let's avoid that.
What you think about me doesn't matter much to anyone. What I think about you matters equally little. However, our writings and behavior on this forum do lead the other readers and posters to form opinions about the both of us. I think that this matters to some extent, especially given that you don't want to describe in detail all of your solutions and you are therefore relying on your general credibility to sell your products.
I don't think that the blowby, ring flutter, and bore wall oil control are "a bunch of basic Engine 101 ideas." I think they are specific problems with the 928 S4 engine. I did the basic computations for the S4 by hand once to find the critical flutter rpm for the S4. I also use a simulator when working on my engine that not only estimates the ring flutter critical rpm but also tracks the flutter-induced blowby over the cycle. This gives and output that is a quantitative estimate of the blowby in each operating condition. Now, the simulator is not perfect and the company that sells the simulator also sells a blowby sensor that tracks the actual amount of blowby in the engine. I don't own that sensor, but I hope buy it some day.
As a side note, specifically about my turbocharged S4 engine, compensating the decline in the volumetric efficiency by increasing the boost has the positive side effect of moving the ring-flutter critical rpm to a much higher level.
I am most assuredly wasting my time. No disagreement there, this entire car project is a hobby.
Now, there's some method to my madness. Currently, I have an engien that works pretty well at the desired rpm range when it stands upright and is not subjected to acceleration forces. However, the engine would most likely not fare well on a track, with sticky tires. My goal is to first understand the 928 oiling system as well as possible and then design a solution to all the potential problems. Maybe I'll succeed, maybe I'll fail, but the fun to me is in the understanding and solving part.
I actually agree that the oil plug in the drain channel is a likely problem and that the engine will burb it into the heads under some conditions. However, the cross-sectional area of those oil drains is mcuh larger than what would be required to drain the oil if the pressure would be equal in the heads and the crankcase. I believe that the problem is caused by the pressure differential supporting the oil plugs and eventually blowing the plug out into the heads. If one eliminates the pressure differential, I don't believe this burbing can happen.
I don't agree with you that it's useful to think about the 928 engine as a single open vessel in which pressures equate immediately. There's a fast spinning crankshaft, there are pistons pumping gas back and forth, for example. These motions in my opinion can support persistently different pressure zones inside a geometrically open or connected crankcase.
Greg, please do not misinterpret me. I didn't say you are dumb. I don't know whether the system on Rob's car picks up multiple locations per stage in the heads or not. In fact, I gave you the benefit of the doubt that they only have one pickup per stage because I didn't want to assume that you are dumb.
I do however stand by my opinion that it's dumb to try to pick up oil with multiple pickups per scavenge pump stage from a system that has both air and oil. If any of the pickups catches air, one will just get air.
I don't think I am putting the cart in front of the horse. Quite the contrary. I want to first understand the problem root causes as completely as possible. With that understanding I want to design my solution for my needs. I also applaud your efforts to think first and build second.
I am absolutely trying to figure out what is happening inside the crankcase. Based on what I think right now, and fully admitting that I may be wrong, I don't think actively scavenging the heads is the best solution. I am trying to challenge and debate you here to figure this out. Perhaps you will present conclusive arguments and empirical data that will lead me to change my mind about what is happening inside the crankcase. I value understanding and knowledge much more than proving someone wrong for the sake of it -- I want to know the truth.
I admit that I am quite annoyed about your marketing antics on this forum. I don't on an emotionally level accept attempts to sell a system without an explanation how it works. On a logical level, I do understand that proprietary information can't be published freely without it losing it's proprietary nature. In any case, I am trying to leave my emotions out of it and simply find out the truth about technical matters by debating other people here, including you.
As a separate matter, I think that intentionally misleading people reading this forum on a technical matter, something to which you admitted to earlier, is completely unacceptable from any perspective.
I am challenging the assertion that you have built the only 928 engine that can run at 6000 rpm for 60 seconds in a stationary upright positition without the heads filling with oil. I simply don't believe it, and certainly you have not proven that. I think it's just over-the-top marketing hype by you.
Counterbalancing my views about your marketing antics, I do admire your dedication to your customers. We don't see many, in fact any, of your customers complaining here. That tells me something. However, let me also say that there may be some potential customers for you here that haven't experienced your dedication first hand and are put off by your marketing style to the point that they never become your customers and never experience being your customer.
It is my understanding about fluid dynamics that fluid does not move without a pressure differential and a pressure differential doesn't exist without fluid movement. Because of this, I think that if oil and air flow from the crankcase from the heads, a pressure differential must exist. Given the velocities and the geometry, I don't think it's useful to think about the heads and the crankcase as a part of the same open vessel.
Whether or not it is accurate, it can't be verified by looking down the chimney of the running engine. You'll just see a bunch of oil churning, but you can't estimate the proportions of the two from that visual. Furthermore, the gas vent angle will materially influence what you pick up from that spot, because oil has much higher density than crankcase gasses. So what you see thru a plexiglass plate on the chimney will not tell you whether my guess is accurate or not.
Perhaps the analogy is not a good one. What I mean is that while every engine has some blowby, with a healthy level being in the neighborhood of 3% of the exhaust gas volume, unhealthy engines push much more blowby to the crankcase. While I don't know anything about your strokers, I firmly believe that the stock S4 engine blowby is normal until either of the two things happens. First, either so much oil gets thrown to the cylinder walls that the oil control is lost and the ring seal with it. Second, the rpm becomes high enough such that the rings "flutter", that is, the inertial forces on the piston rings overcome the pressure differential between the combustion chamber and the crankcase. In either of those cases, the blowby increases dramatically and all sorts of trouble starts. Attempting to relieve the symptoms with crankcase evacuation systems may mitigate the damage but will not address the underlying true causes of the problems.
I am trying to keep this completely technical as much as I can. However, I will, reluctantly, respond to ad hominem stuff in kind. Please let's avoid that.
What you think about me doesn't matter much to anyone. What I think about you matters equally little. However, our writings and behavior on this forum do lead the other readers and posters to form opinions about the both of us. I think that this matters to some extent, especially given that you don't want to describe in detail all of your solutions and you are therefore relying on your general credibility to sell your products.
I don't think that the blowby, ring flutter, and bore wall oil control are "a bunch of basic Engine 101 ideas." I think they are specific problems with the 928 S4 engine. I did the basic computations for the S4 by hand once to find the critical flutter rpm for the S4. I also use a simulator when working on my engine that not only estimates the ring flutter critical rpm but also tracks the flutter-induced blowby over the cycle. This gives and output that is a quantitative estimate of the blowby in each operating condition. Now, the simulator is not perfect and the company that sells the simulator also sells a blowby sensor that tracks the actual amount of blowby in the engine. I don't own that sensor, but I hope buy it some day.
As a side note, specifically about my turbocharged S4 engine, compensating the decline in the volumetric efficiency by increasing the boost has the positive side effect of moving the ring-flutter critical rpm to a much higher level.
I am most assuredly wasting my time. No disagreement there, this entire car project is a hobby.
Now, there's some method to my madness. Currently, I have an engien that works pretty well at the desired rpm range when it stands upright and is not subjected to acceleration forces. However, the engine would most likely not fare well on a track, with sticky tires. My goal is to first understand the 928 oiling system as well as possible and then design a solution to all the potential problems. Maybe I'll succeed, maybe I'll fail, but the fun to me is in the understanding and solving part.
I actually agree that the oil plug in the drain channel is a likely problem and that the engine will burb it into the heads under some conditions. However, the cross-sectional area of those oil drains is mcuh larger than what would be required to drain the oil if the pressure would be equal in the heads and the crankcase. I believe that the problem is caused by the pressure differential supporting the oil plugs and eventually blowing the plug out into the heads. If one eliminates the pressure differential, I don't believe this burbing can happen.
I don't agree with you that it's useful to think about the 928 engine as a single open vessel in which pressures equate immediately. There's a fast spinning crankshaft, there are pistons pumping gas back and forth, for example. These motions in my opinion can support persistently different pressure zones inside a geometrically open or connected crankcase.
Greg, please do not misinterpret me. I didn't say you are dumb. I don't know whether the system on Rob's car picks up multiple locations per stage in the heads or not. In fact, I gave you the benefit of the doubt that they only have one pickup per stage because I didn't want to assume that you are dumb.
I do however stand by my opinion that it's dumb to try to pick up oil with multiple pickups per scavenge pump stage from a system that has both air and oil. If any of the pickups catches air, one will just get air.
I don't think I am putting the cart in front of the horse. Quite the contrary. I want to first understand the problem root causes as completely as possible. With that understanding I want to design my solution for my needs. I also applaud your efforts to think first and build second.
I am absolutely trying to figure out what is happening inside the crankcase. Based on what I think right now, and fully admitting that I may be wrong, I don't think actively scavenging the heads is the best solution. I am trying to challenge and debate you here to figure this out. Perhaps you will present conclusive arguments and empirical data that will lead me to change my mind about what is happening inside the crankcase. I value understanding and knowledge much more than proving someone wrong for the sake of it -- I want to know the truth.
I admit that I am quite annoyed about your marketing antics on this forum. I don't on an emotionally level accept attempts to sell a system without an explanation how it works. On a logical level, I do understand that proprietary information can't be published freely without it losing it's proprietary nature. In any case, I am trying to leave my emotions out of it and simply find out the truth about technical matters by debating other people here, including you.
As a separate matter, I think that intentionally misleading people reading this forum on a technical matter, something to which you admitted to earlier, is completely unacceptable from any perspective.
I am challenging the assertion that you have built the only 928 engine that can run at 6000 rpm for 60 seconds in a stationary upright positition without the heads filling with oil. I simply don't believe it, and certainly you have not proven that. I think it's just over-the-top marketing hype by you.
Counterbalancing my views about your marketing antics, I do admire your dedication to your customers. We don't see many, in fact any, of your customers complaining here. That tells me something. However, let me also say that there may be some potential customers for you here that haven't experienced your dedication first hand and are put off by your marketing style to the point that they never become your customers and never experience being your customer.
I design and build stuff that works. Period. My record of building engines, transmissions, parts for the 928 vehicle, stands on its own. Everything gets tested and proven, long before it sold to any customer. Anything that I make, if it doesn't work, can be returned and the customer can get a full cash refund. (BTW...I can't think of a single example of that happening!)
I do not "enjoy" or have any regard for people that build things that don't work or are not tested. That has been very obvious, here. That is not part of my "marketing plan". I simply have no regard for people that I believe are "ripping" people off.
I do not feel the need to tell everyone how to build their own ventilation system, at home. I do not feel the need to teach C3 how to build one. I'm sorry if you think that "mis-leading" information hurts my credibility.....but I'm quite simply, not going to tell you (or anyone) how to do it. I've literally (and clearly) invested 10's of thousands of dollars in this effort. There are many of both systems out there running around....ask the people that have then, if their problems have been solved....before you come here and try to criticize what I've done.
Reality trumps opinions.
Clearly, your intentions are not to understand my systems, but to attack what I've done....you virtually say so, above. I'm not mad. I'm not sending things off to the moderators, whining about you doing this....I can deal with it.
At this point, I'd suggest that you figure this out, on your own....BTW....did you know enough to build your own engine?