Space vane body and method of manufacturing the same

Abstract

The application provides a space guide vane body, which comprises an injection-molded shell, a flow guide core and an insert piece. A containing cavity is formed in the shell and extends through both ends of the shell. The flow guide core is arranged in the containing cavity and is connected to the shell in position. An installation groove corresponding to the flow guide core is formed in the inner side wall of the shell. The insert piece is inserted into the installation groove. A boss is formed on the flow guide core. The boss cooperates with the installation groove and the insert piece to position the flow guide core in the containing cavity of the shell. The application also provides a manufacturing method of the space guide vane body. The shell, the flow guide core and the insert piece are manufactured by using an injection molding process. The flow guide core is installed into the shell. The boss is inserted into the installation groove. Solvent glue is uniformly applied on the surface of the insert piece. The insert piece is inserted into the installation groove until the insert piece contacts the boss. The product is obtained after air drying. The injection-molded parts are assembled by using glue. The overall structure is simple. The internal connection is firm. The requirements of injection-molded demolding and lightweight production of the space guide vane body are met.

Description

Technical Field

[0001] This invention relates to the field of space guide vane manufacturing technology, and particularly to space guide vanes and their manufacturing methods. Background Technology

[0002] The guide vane is a crucial component in centrifugal water pumps that converts mechanical energy into liquid potential energy. The pump, driven by a prime mover (electric motor or internal combustion engine), rotates its impeller at high speed, converting the mechanical energy of rotation into the pressure and velocity potential energy of the liquid, with velocity potential energy accounting for a larger proportion than pressure potential energy. Since the velocity potential energy of a liquid is difficult to utilize, the pump must convert it into pressure potential energy for practical use; the guide vane is the component that performs this conversion.

[0003] A spatial guide vane is a semi-enclosed structure composed of multiple three-dimensional curved surfaces. Traditionally, spatial guide vanes were manufactured through metal casting or stamping and welding. Metal-cast spatial guide vanes are formed by integral sand casting; the collapsibility of the casting core makes casting relatively easy, allowing for one-piece molding. However, the casting core cannot be reused, resulting in low production efficiency. Stamped spatial guide vanes involve stamping multiple spatial curved surfaces separately, then assembling them internally and spot-welding them. This production method is more complex due to the large number of assembled parts and numerous processing steps. In summary, spatial guide vanes manufactured using traditional processes are relatively heavy, have high manufacturing costs, and low processing efficiency, making it difficult to meet the current requirements for lightweight and high-efficiency water pump manufacturing.

[0004] With the increasing demands for lighter pumps, lower manufacturing costs, and higher efficiency, the use of plastics in pump component manufacturing has become a major trend in small pump production. Therefore, designing and manufacturing plastic spacer vanes is imperative. However, due to the semi-enclosed structure of spacer vanes, they cannot be manufactured using traditional one-piece injection molding (the inner core cannot be removed), nor can they be manufactured using welding (due to the inherent limitations of plastic's low strength and the characteristics of plastic welding processes). Therefore, it is necessary to develop a structure and process that can meet the requirements of plastic spacer vane manufacturing. Summary of the Invention

[0005] This invention provides a spatial guide vane, assembled from a specifically constructed shell, a guide core, and inserts. All three components—shell, guide core, and inserts—are open structures, manufactured using injection molding. The spatial guide vane achieves sufficient mechanical strength to meet design requirements while simultaneously being lightweight, with low manufacturing costs and high production efficiency. Correspondingly, this invention also provides a method for manufacturing the spatial guide vane, which is simple, easy to implement, and conducive to industrial application.

[0006] To solve the above-mentioned technical problems, the present invention discloses a spatial guide vane, comprising: an injection-molded shell, a guide core, and inserts; the shell has a receiving cavity that communicates with both ends of the shell, the receiving cavity is used for liquid flow, and the guide core is disposed in the receiving cavity and is limitedly connected to the shell; the inner sidewall of the shell has a mounting groove corresponding to the guide core, the inserts are inserted into the mounting groove, the blades on the guide core have protrusions, the protrusions cooperate with the mounting groove and the inserts to limit the guide core in the receiving cavity; the contact parts of the shell, the guide core, and the inserts are fixed by adhesive.

[0007] In the technical solution of this invention, the spatial guide vane is assembled from a shell, a guide core, and inserts with a specific structure. The shell, guide core, and inserts are all open structures, obtained using injection molding. The spatial guide vane achieves sufficient mechanical strength to meet design requirements while simultaneously being lightweight, with low manufacturing cost and high production efficiency. Specifically:

[0008] 1. A semi-enclosed structural part that cannot be demolded is split into three open parts, which meets the requirements for injection molding demolding and has good manufacturing feasibility.

[0009] 2. Since all parts are injection molded, production efficiency is greatly improved.

[0010] 3. Because it is made of plastic, its overall weight is only one-half to one-quarter of that of metal.

[0011] 4. Due to increased production efficiency and reduced overall weight, the cost is significantly lower than that of metal manufacturing.

[0012] Furthermore, the inner wall of the housing includes: a first cylindrical surface, a second cylindrical surface, and an arc surface; the first cylindrical surface and the second cylindrical surface are respectively disposed at both ends of the inner wall of the housing, and the two sides of the arc surface are respectively connected to the first cylindrical surface and the second cylindrical surface.

[0013] In the technical solution of this invention, since each three-dimensional curved surface that makes up the flow channel is injection molded, the surface finish is high and the flow resistance is low, which effectively reduces energy loss in the energy conversion process.

[0014] Furthermore, the outer wall of the housing is symmetrically provided with lifting lug holes, and the outer wall of the housing is also provided with a nameplate mounting boss, which is located at the central axis position of the two lifting lug holes.

[0015] In the technical solution of this invention, the lifting lug hole facilitates the hoisting and transportation or hoisting and assembly of the housing, the assembled space guide vane body, and the water pump as a whole. The nameplate mounting boss facilitates the installation of the nameplate. Both the nameplate mounting boss and the lifting lug hole are integrally formed with the housing, resulting in a simple overall structure and minimal space occupation.

[0016] Furthermore, the mounting groove is a dovetail groove, and an inclined groove surface is formed on the inner side of the mounting groove. When the flow guide core is installed into the housing, the boss cooperates with the inclined groove surface. A limiting mounting area is formed between the insert and the inclined groove surface. The boss is located in the limiting mounting area and limits the flow guide core to be located in the housing.

[0017] In the technical solution of this invention, the dovetail groove and the installation area can respectively limit the position of the insert and the boss, effectively preventing the guide core and the insert from falling off during use. The limiting and fixing effect is good, and the insert is a straight insertion method, which makes the installation and operation convenient.

[0018] Furthermore, one end of the mounting groove is formed on the arc surface, and the other end is formed through the first cylindrical surface. When the guide core is installed into the housing, the dimensions of the boss and the insert are the same as the dimensions of the mounting groove.

[0019] In the technical solution of the present invention, the boss and the insert are completely fitted with the dimensions of the mounting groove after installation, so that the boss and the insert are subjected to uniform force and the internal structure is reasonable.

[0020] Furthermore, the flow guide core includes: a core body and a plurality of flow guide blades disposed on the core body; the flow guide blades divide the flow space between the core body and the inner wall of the housing into a plurality of curved flow channels of the same size, and the protrusions correspond to the mounting grooves respectively when the flow guide core is installed into the housing.

[0021] In the technical solution of this invention, the guide vanes divide the flow space into curved channels to make the internal flow velocity change uniformly, and can effectively reduce energy loss when the liquid velocity potential energy is converted into pressure potential energy. The internal structure is reasonably set, and the guide vanes and the mounting groove can limit the guide core and improve the stability of the internal structure.

[0022] Furthermore, the guide vane includes an outer circular surface, the boss is disposed on the outer circular surface of the guide vane, and the boss, the guide vane and the core are integrally formed.

[0023] In the technical solution of the present invention, the boss is provided on the outer circumferential surface of the guide vane. When the guide core is installed in the housing, it does not affect the fit between the guide vane and the inner wall of the housing. At the same time, the boss and the mounting groove can limit the guide core in the housing, preventing the guide core from rotating or falling off due to the impact of the liquid velocity potential energy, thus making the internal structure more stable.

[0024] Furthermore, one end of the insert has a beveled surface, which engages with the boss when installed on the space guide vane body; wherein the beveled surface includes a tip and a connecting portion, the tip is higher than the connecting portion, and the tip and the connecting portion form an arc transition.

[0025] In the technical solution of the present invention, the inclined baffle allows the insert to engage with the boss when it is installed in the mounting groove. The tip and the connecting part allow the end of the insert placed inside the housing to fit against the inner wall of the housing and form a curved transition, thus preventing the upper end of the insert from being higher than the inner wall of the housing and thus affecting the conversion of liquid velocity potential energy.

[0026] The aforementioned method for manufacturing the space guide vane of the present invention includes the following steps:

[0027] ① The shell, flow guide core, and insert are manufactured separately using injection molding technology;

[0028] ② The shell, guide core, and insert are deburred and then cleaned.

[0029] ③ Apply the solvent adhesive evenly to the mounting groove of the housing and the outer surface of the guide vanes of the guide core;

[0030] ④ Install the guide core into the housing so that the outer circular surface of the guide blade contacts the arc surface inside the housing, and at the same time insert the boss into the mounting groove and contact the inclined groove surface of the mounting groove.

[0031] ⑤ Apply solvent adhesive evenly to the surface of the insert, then insert it into the mounting groove until the insert contacts the boss, and air dry to obtain the product.

[0032] The manufacturing process of this invention is simple, easy to implement, and conducive to industrial promotion. Attached Figure Description

[0033] Figure 1 This is a perspective view of the spatial guide vane body of the present invention;

[0034] Figure 2 This is a front view of the space guide vane body of the present invention;

[0035] Figure 3 A perspective view of the spatial guide vane body of the present invention with the guide core removed;

[0036] Figure 4 This is a perspective view of the space guide vane housing of the present invention;

[0037] Figure 5 This is a rear-view perspective view of the space guide vane housing of the present invention;

[0038] Figure 6 This is a perspective view of the guide vane core of the present invention.

[0039] Figure 7 This is a schematic diagram of the spatial guide vane core structure of the present invention;

[0040] Figure 8 This is a perspective view of the space guide vane insert of the present invention;

[0041] Figure 9 This is a front view of the space guide vane insert of the present invention;

[0042] Wherein: 1 is the shell, 101 is the first cylindrical surface, 102 is the arc surface, 103 is the second cylindrical surface, 2 is the guide core, 201 is the core body, 202 is the guide vane, 212 is the outer circular surface of the guide vane, 3 is the insert, 4 is the flange, 401 is the first flange, 402 is the second flange, 5 is the receiving cavity, 6 is the mounting groove, 601 is the inclined groove surface, 7 is the boss, 8 is the lifting lug hole, 9 is the nameplate mounting boss, 10 is the curved flow channel, 11 is the limiting installation area, 12 is the inclined baffle, 1201 is the tip, and 1202 is the connecting part. Detailed Implementation

[0043] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and are not intended to limit the scope of the invention. Content not described in detail below is common knowledge in the art.

[0044] See Figures 1-9 The space guide vane body includes: an injection-molded shell 1, a flow guide core 2, and a blade 3; the shell 1 has a receiving cavity 5 that communicates with both ends of the shell 1, the flow guide core 2 is located in the receiving cavity 5 and is limited and connected to the shell 1; the inner side wall of the shell 1 has a mounting groove 6 corresponding to the flow guide core 2, the blade 3 is inserted into the mounting groove 6, the blade on the flow guide core 2 has a boss 7, the boss 7 cooperates with the mounting groove 6 and the blade 3 and limits the flow guide core 2 in the receiving cavity 5 of the shell 1, and the contact parts of the shell 1, the flow guide core 2, and the blade 3 are fixed by adhesive.

[0045] Thus, the two ends of the housing 1 are connected to other external water pump parts through flanges 4. The space formed by the inner surface 1 of the housing, the core 201, and the guide vanes 202 is used for liquid flow and the conversion of velocity potential energy into pressure potential energy. The flanges 4 include a first flange 401 and a second flange 402, which are respectively located at the two ends of the housing 1. The spatial guide vane body is assembled from a housing 1 with a specific structure, a guide core 2, and inserts 3. The housing 1, the guide core 2, and the inserts 3 are all open structures, obtained by injection molding. The mechanical strength of the spatial guide vane body can meet the design requirements, while achieving lightweighting of the spatial guide vane body, low manufacturing cost, and high production efficiency. Specifically, it is manifested in the following ways: a semi-closed structure part that cannot be demolded is split into three open parts, which meets the requirements of injection molding demolding and has good manufacturing feasibility; since all parts are injection molded, the production efficiency is greatly improved; since it is made of plastic, the overall weight is only one-half to one-quarter of that of metal manufacturing; due to the improved production efficiency and reduced overall weight, the cost is greatly reduced compared to metal manufacturing.

[0046] See Figure 3 , Figure 4 and Figure 5 In a specific embodiment, the inner wall of the housing 1 includes: a first cylindrical surface 101, an arc surface 102, and a second cylindrical surface 103; the first cylindrical surface 101 and the second cylindrical surface 103 are respectively disposed at both ends of the inner wall of the housing 1, and the two sides of the arc surface 102 are respectively connected to the first cylindrical surface 101 and the second cylindrical surface 103.

[0047] Thus, the first cylindrical surface 101 and the second cylindrical surface 103 form cylindrical inner surfaces. The first cylindrical surface 101 and the second cylindrical surface 103 are integrally connected with the arc surface 102. The outer circumferential surface of the guide core 2 is matched with the arc surface 102. Since each three-dimensional curved surface that makes up the flow channel is injection molded, the surface finish is high and the flow resistance is low, effectively reducing energy loss in the energy conversion process.

[0048] See Figure 1 and Figure 2 In a specific embodiment, lifting lug holes 8 are symmetrically arranged on the outer wall of the housing 1, and nameplate mounting bosses 9 are also provided on the outer wall of the housing 1. The nameplate mounting bosses 9 are located at the central axis position of the lifting lug holes 8 on both sides.

[0049] Therefore, the lifting lug 8 and the nameplate mounting boss 9 are integrally formed with the housing 1. The lifting lug 8 facilitates the hoisting and transportation or hoisting and assembly of the housing 1, the assembled guide vane body, and the water pump as a whole. The nameplate mounting boss 9 facilitates the installation of the nameplate. The overall structure is simple and occupies little space.

[0050] See Figure 3 , Figure 4 and Figure 5In a specific embodiment, the mounting groove 6 is a dovetail groove, and an inclined groove surface 601 is formed on the inner side of the mounting groove 6. When the guide core 2 is installed into the housing 1, the boss 7 cooperates with the inclined groove surface 601. A limiting installation area 11 is formed between the insert 3 and the inclined groove surface 601. The boss 7 is located in the limiting installation area 11 and limits the guide core 2 to be located in the housing 1.

[0051] Therefore, the dovetail groove 6 and the installation area 11 can respectively limit the insertion plate 3 and the boss, effectively preventing the guide core 2 and the insertion plate 7 from falling off during use. The limiting and fixing effect is good, and the insertion plate is a straight insertion method, which makes the installation and operation convenient.

[0052] See Figure 4 In a specific embodiment, one end of the mounting groove 6 is opened on the arc surface 102, and the other end is opened through the first cylindrical surface 101. When the guide core 2 is installed into the housing 1, the size of the boss 7 and the insert 3 is the same as the size of the mounting groove 6.

[0053] Therefore, after installation, the boss 7 and the insert 3 fit perfectly with the dimensions of the mounting groove 6, so that the boss 7 and the insert 3 are subjected to uniform force and the internal structure is reasonable.

[0054] See Figure 6 and Figure 7 In a specific embodiment, the flow guide core 2 includes: a core body 201 and a plurality of flow guide blades 202 disposed on the core body 201; the flow guide blades 202 divide the flow space between the core body 201 and the inner wall of the housing 1 into a plurality of curved flow channels 10 of the same size, and the bosses 7 correspond to the mounting grooves 6 respectively when the flow guide core 2 is installed in the housing 1.

[0055] Therefore, the guide vane 202 divides the flow space into curved flow channels 10, making the internal flow velocity change uniformly. Furthermore, it effectively reduces energy loss when the liquid's velocity potential energy is converted into pressure potential energy. The internal structure is rationally designed; the boss 7 and the mounting groove 6 correspond to each other and can limit the movement of the guide core 2, improving the stability of the internal structure.

[0056] See Figure 6 and Figure 7 In a specific embodiment, the guide vane 202 includes an outer circular surface 212 of the guide vane, and a boss 7 is provided on the outer circular surface 212 of the guide vane. The boss 7, the guide vane 202 and the core 201 are integrally formed structures.

[0057] Therefore, the boss 7 is provided on the outer circumferential surface of the guide vane 202. When the guide core 2 is installed in the housing 1, it does not affect the fit between the guide vane 202 and the inner wall of the housing 1. At the same time, the boss 7 and the mounting groove 6 can limit the guide core 202 in the housing 1, preventing the guide core 2 from rotating or falling off due to the impact of the liquid velocity potential energy, thus making the internal structure more stable.

[0058] See Figure 8 and Figure 9 In a specific embodiment, one end of the insert 3 is formed with a beveled baffle 12, which cooperates with the boss 7 when it is installed on the space guide vane body; wherein, the beveled baffle 12 includes a tip 1201 and a connecting part 1202, the tip 1201 is higher than the connecting part 1202 from the insert 3, and the tip 1201 to the connecting part 1202 has an arc transition.

[0059] Therefore, the inclined baffle 12 enables the insert 3 to engage with the boss 7 when it is installed in the mounting groove 6. The tip 1201 and the connecting part 1202 make the end of the insert 3 placed inside the housing 1 fit against the inner wall of the housing 1 and form a curved arc transition, thus preventing the upper end surface of the insert 3 from being higher than the inner wall surface of the housing 1 and thus affecting the conversion of liquid velocity potential energy.

[0060] This embodiment breaks down a semi-enclosed structural part that cannot be demolded into three open parts, which meets the requirements for injection molding and demolding of the space guide vane, making the overall weight of the space guide vane lighter and reducing the cost compared to metal manufacturing, while also increasing production efficiency. Through the cooperation of bosses, inserts, and mounting slots, the internal structure of the space guide vane is more stable after assembly, avoiding energy loss caused by the impact of the liquid's huge velocity potential energy, improving energy conversion efficiency, meeting the production requirements of lightweight space guide vanes, and improving their hydraulic performance.

[0061] The manufacturing method of the space guide vane body is as follows: ① The shell 1, the guide core 2, and the insert 3 are manufactured by injection molding (in this embodiment, the injection molding material is reinforced nylon); ② The shell 1, the guide core 2, and the insert 3 are deburred and then cleaned; ③ Solvent adhesive is evenly applied to the mounting groove 6 of the shell 1 and the outer circular surface of the guide vane 202 of the guide core 2; ④ The guide core 2 is installed into the shell 1 so that the outer circular surface of the guide vane 202 contacts the arc surface inside the shell 1, and the boss 7 is inserted into the mounting groove 6 and contacts the inclined groove surface 601 of the mounting groove 6; ⑤ Solvent adhesive is evenly applied to the surface of the insert 3, and then it is inserted into the mounting groove 6 until the insert 3 contacts the boss 7, and then air-dried to obtain the product.

[0062] In this embodiment, the shell and the guide core are formed separately by injection molding, which meets the production requirements of lightweight space guide vanes and realizes the injection molding of space guide vane parts. Assembling the three parts improves production efficiency, reduces the number of parts and reduces manufacturing costs. In addition, the parts are bonded together with solvent adhesive, so there is no additional structure at the connection between the parts. The manufacturing process of the space guide vane is simple.

[0063] The above are merely preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A space guide vane body, characterized in that: The device includes an injection-molded housing (1), a flow guide (2), and a insert (3). The housing (1) has a cavity (5) that communicates with both ends of the housing (1). The flow guide (2) is located in the cavity (5) and is connected to the housing (1) for a limiting connection. The inner wall of the housing (1) has a mounting groove (6) corresponding to the flow guide (2). The insert (3) is inserted into the mounting groove (6). The blades of the flow guide (2) have protrusions (7). The protrusions (7) cooperate with the mounting groove (6) and the insert (3) and limit the flow guide (2) in the cavity (5) of the housing (1). The contact parts of the housing (1), the flow guide (2), and the insert (3) are fixed by adhesive. The mounting groove (6) is a dovetail groove, and an inclined groove surface (601) is formed on the inner side of the mounting groove (6). The boss (7) cooperates with the inclined groove surface (601) when the guide core (2) is installed into the housing (1). The flow guide core (2) includes: a core body (201) and a plurality of flow guide blades (202) disposed on the core body (201); the flow guide blades (202) divide the flow space between the core body (201) and the inner wall of the housing (1) into a plurality of curved flow channels (10) of the same size, and the bosses (7) correspond to the mounting grooves (6) respectively when the flow guide core (2) is installed in the housing (1); The manufacturing method of the space guide vane includes the following steps: ① The shell (1), the flow guide core (2) and the insert (3) are manufactured by injection molding process respectively; ② The shell (1), the guide core (2) and the insert (3) are deburred and then the surfaces are cleaned; ③ Apply solvent adhesive evenly to the mounting groove (6) of the housing (1) and the outer surface of the guide vane (202) of the guide core (2); ④ Install the guide core (2) into the housing (1) so that the outer circular surface of the guide blade (202) contacts the arc surface inside the housing (1), and at the same time insert the boss (7) into the mounting groove (6) and contact the inclined groove surface (601) of the mounting groove (6); ⑤ Apply solvent adhesive evenly to the surface of the insert (3), then insert it into the mounting groove (6) until the insert (3) contacts the boss (7), and air dry to obtain the product.

2. The space guide vane body as described in claim 1, characterized in that: The inner wall of the shell (1) includes: a first cylinder Surface (101), curved surface (102) and second cylinder Surface (103); the first cylinder Surface (101) and the second cylinder Surfaces (103) are respectively provided at both ends of the inner wall of the shell (1), and the two sides of the arc surface (102) are respectively connected to the first cylinder Surface (101) and the second cylinder Connect the face (103).

3. The space guide vane body as described in claim 1, characterized in that: The outer wall of the housing (1) is symmetrically provided with lifting lug holes (8), and the outer wall of the housing (1) is also provided with a nameplate mounting boss (9), which is located at the central axis position of the two lifting lug holes (8).

4. The space guide vane body as described in claim 1, characterized in that: A limiting installation area (11) is formed between the insert (3) and the inclined groove surface (601). The boss (7) is located in the limiting installation area (11) and limits the flow guide core (2) in the housing (1).

5. The space guide vane body as described in claim 2, characterized in that: One end of the mounting groove (6) is formed on the arc surface (102), and the other end is formed through the first... cylinder On the surface (101), when the flow guide core (2) is installed into the housing (1), the dimensions of the boss (7) and the insert (3) are the same as the dimensions of the mounting groove (6).

6. The space guide vane body as described in claim 1, characterized in that: The guide vane (202) includes an outer circular surface (212) of the guide vane, and the boss (7) is provided on the outer circular surface (212) of the guide vane. The boss (7), the guide vane (202) and the core (201) are integrally formed.

7. The space guide vane body as described in claim 1, characterized in that: One end of the insert (3) is formed with a beveled baffle (12), which cooperates with the boss (7) when it is installed on the space guide vane body; wherein, the beveled baffle (12) includes a tip (1201) and a connecting part (1202), the tip (1201) is higher than the connecting part (1202) from the insert (3), and the tip (1201) to the connecting part (1202) is arc-shaped transition.

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