Bent Pipe Segmentation for Core-Less Oil Separator Molding
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Solution Overview
Problem
The existing centrifugal separation-type oil separators face challenges in manufacturing due to the need for a core to support the bent pipe's molding, which is unstable and difficult to maintain, especially at the inflow and outflow ports, leading to instability in forming the oil separator.
Innovation Solution
The outer and inner wall portions of the bent pipe are constituted by different members, allowing for core-less formation, with an integral upper cover and inner cylinder, and a positioning mechanism to ensure accurate alignment and prevent displacement of the outflow port, facilitating easier assembly and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the outer wall portion and inner wall portion of the bent pipe are integrally molded by casting, then the bent pipe structure is unified and strong, but a core is required for molding which makes the manufacturing process complex and unstable
Solution Approach 1:
The bent pipe is divided into two separate members: the outer wall portion and the inner wall portion. This segmentation eliminates the need for a complex core structure during molding, as each component can be manufactured independently using simpler molding processes, thereby resolving the contradiction between structural strength and manufacturing ease.
Solution Approach 2:
The inner wall portion is positioned inside the outer wall portion, creating a nested configuration. This nesting arrangement maintains the structural integrity and strength of the bent pipe while allowing both components to be molded separately without requiring complex core support structures, thus solving the manufacturing complexity issue.
2Manufacturing precision
If a core is used to mold the bent pipe, then the internal flow path shape can be formed, but the core cannot be stably supported at inflow and outflow ports making manufacturing difficult
Solution Approach 1:
By segmenting the bent pipe into outer and inner wall portions, the internal flow path shape is formed by the relative positioning of these two members rather than by a supported core. This eliminates the core support stability problem while maintaining manufacturing precision through the nested configuration of the segmented components.
Solution Approach 2:
The outer wall portion acts as an intermediary structure that defines the external shape and provides support, while the inner wall portion defines the internal flow path. This intermediary relationship between the two members eliminates the need for a separate core, resolving both the support stability and shape precision requirements.
3Strength
If the bent pipe is formed as a single integral component, then structural strength is improved, but manufacturing time and cost increase due to complex molding requirements
Solution Approach 1:
The bent pipe is segmented into outer and inner wall portions that can be manufactured independently using simpler, faster molding processes. This segmentation improves productivity by eliminating complex core requirements while maintaining structural strength through the nested assembly of the two components.
Solution Approach 2:
The outer wall portion and inner wall portion are combined in a nested configuration to form the complete bent pipe structure. This merging of separately manufactured components achieves the structural strength of an integral component while benefiting from the manufacturing efficiency of separate, simpler molding processes.
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 solution enables stable and efficient manufacturing of the oil separator, reduces manufacturing time and costs, and ensures reliable operation by preventing incorrect assembly and maintaining effective oil separation efficiency.
Implementation Method 1
centrifugal separation-type oil separator
Data Source
Figure 1
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AI summary
A bent pipe (70) includes an outer wall portion (71) extending in the circumferential direction of a body portion (53) and expanding radially outward from the body portion (53); and an inner wall portion (72) extending along the outer wall portion (71) and blocking a radially inner-side open part of the outer wall portion (71). The outer wall portion (71) and the inner wall portion (72) are constituted by different members.