Additive Pump Housing Layout Without Internal Support Structures
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Solution Overview
Problem
Traditional fuel pump manufacturing methods and designs make it difficult to additively manufacture fuel pumps that are both economical and effective, as they require non-build plate support structures within internal apertures, which are costly and inefficient.
Innovation Solution
The method involves additively manufacturing a fluid pump case in a tilted orientation without non-build plate support structures, except for coincidental locations intended for post-processing milling, allowing for the elimination of support structures and enabling efficient production of fuel pumps using laser powder bed fusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional molding and machining methods are used for fuel pump manufacturing, then manufacturing precision and reliability are maintained, but manufacturing cost increases and productivity decreases
Solution Approach 1:
The patent changes the manufacturing method from traditional molding and machining to additive manufacturing, fundamentally altering the production parameters. This enables complex internal geometries to be manufactured directly without multiple machining operations, reducing both cost and production time while maintaining precision
Solution Approach 2:
The patent utilizes the third dimension in additive manufacturing to create complex internal apertures and valve body features that would require multiple machining steps in traditional manufacturing. This dimensional approach allows support structures to be strategically placed only where geometrically necessary, eliminating unnecessary support removal operations
2Shape
If non-build plate support structures are used in internal apertures during additive manufacturing, then geometric complexity is achieved, but manufacturing cost increases and support removal time is required
Solution Approach 1:
The patent extracts and eliminates unnecessary support structures from the internal aperture geometry by carefully selecting build orientations. Only coincidental support structures are retained at locations where post-process milling is already planned, removing the need for separate support removal operations and reducing manufacturing cost
Solution Approach 2:
The patent performs preliminary build orientation selection to position the part such that gravity and build direction naturally eliminate the need for support structures in internal apertures. This preliminary action prevents the need for costly support removal operations while maintaining the required geometric complexity
3Strength
If build plate support structures are used in internal apertures, then structural support during building is provided, but support removal activities are required which increase manufacturing time
Solution Approach 1:
The patent designs the build orientation and geometry such that the part itself provides the necessary structural support during the additive manufacturing process. The part geometry is configured to be self-supporting in the selected build direction, eliminating the need for additional support structures and the subsequent time-consuming removal operations
4Adaptability or versatility
If additive manufacturing is used for fluid pump case, then manufacturing flexibility and complexity are improved, but support structure requirements increase
Solution Approach 1:
The patent employs asymmetric build orientation selection tailored to the specific geometry of the fluid pump case. By orienting the part at specific angles relative to the build plate, the design leverages the asymmetric nature of additive manufacturing to eliminate support structures in internal apertures while maintaining the required design flexibility and complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces manufacturing costs, maintains or improves part performance, and eliminates the need for support removal activities, resulting in fuel pumps that are cost-effective and performance-comparable to traditionally casted parts.
Implementation Method 1
additively manufacturing a fluid pump case in a tilted orientation without any non-build plate support structure in any internal apertures of the fluid pump case... additively manufacturing a fluid pump case layer by layer... operating an additively manufacturing machine to build a fluid pump case layer by layer
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
In accordance with at least one aspect of this disclosure, embodiments of fluid pumps, pump cases, valve bodies, and volutes are disclosed herein. Embodiments of methods for manufacturing fluid pumps, pump cases, valve bodies, and volutes are also disclosed herein. Embodiments can include additive manufacturing, for example. Certain embodiments can include additively manufacturing a pump case in a tilted orientation, utilizing only coincidental support structure having a unique shape, and with teardrop shaped volute and/or valve body.