Closed Impeller Fusion Using Conical Guide Surfaces
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Solution Overview
Problem
Existing methods for manufacturing closed impellers face challenges with radial displacement during fusion, leading to reduced service life and pump capacity due to eccentric centrifugal forces and inefficient fusion processes.
Innovation Solution
A method involving the formation of a frustum-shaped front plate and a disk-shaped base plate with sharp-pointed ridge-like protrusions on the impeller blade tip surfaces, allowing for accurate alignment and fusion without grooves, using vibrations to melt the protrusions and align the front plate centrally, ensuring precise attachment and increased productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional fusion methods (ultrasonic waves, vibrations, laser, heat plate, high-frequency radiation) are used to fuse the front plate with the impeller blade, then the components can be integrated to form a closed impeller, but radial displacement occurs during fusion leading to reduced manufacturing precision and reliability
Solution Approach 1:
The patent applies preliminary action by pre-forming conical guide surfaces on both the front plate and impeller blade before the fusion process. These guide surfaces are prepared in advance to ensure accurate alignment and prevent radial displacement during the subsequent fusion operation, thereby resolving the contradiction between ease of manufacture and manufacturing precision.
Solution Approach 2:
The conical guide surfaces act as an intermediary mechanism between the front plate and impeller blade. These surfaces facilitate proper alignment and positioning during fusion by providing a geometric interface that guides the components into correct relative positions, eliminating radial displacement while maintaining manufacturing precision.
2Ease of manufacture
If the front plate is fused to the impeller blade using conventional methods, then the closed impeller structure is achieved, but eccentric centrifugal forces are generated reducing bearing service life
Solution Approach 1:
The conical guide surfaces are pre-formed on both components to ensure accurate alignment before fusion. This preliminary geometric configuration prevents eccentric positioning that would generate harmful centrifugal forces, thereby extending bearing service life while maintaining ease of integration.
Solution Approach 2:
The patent applies preliminary anti-action by designing the conical guide surfaces to preemptively counteract potential radial displacement and eccentric positioning. The geometric constraint built into the guide surfaces prevents the formation of eccentric centrifugal forces before they can occur during operation, thus protecting bearing reliability.
3Manufacturing precision
If positioning members are used to prevent radial displacement during fusion, then manufacturing precision is improved, but device complexity and productivity are reduced
Solution Approach 1:
The patent extracts and eliminates the need for separate positioning members by integrating the alignment function directly into the conical guide surfaces that are formed as integral parts of the front plate and impeller blade. This removes the additional positioning components while maintaining manufacturing precision.
Solution Approach 2:
The conical guide surfaces serve multiple functions: they provide geometric alignment, prevent radial displacement, and facilitate fusion positioning all in one integrated feature. This multi-functionality eliminates the need for separate positioning members, reducing device complexity while maintaining manufacturing precision.
4Ease of manufacture
If the front plate is fused without accurate alignment, then manufacturing simplicity is maintained, but pump capacity and discharge performance are reduced
Solution Approach 1:
The conical guide surfaces are pre-formed to ensure accurate alignment of the front plate with the impeller blade axis. This preliminary geometric configuration maintains manufacturing simplicity by providing self-alignment during fusion, while simultaneously ensuring that the front plate is positioned correctly to maintain optimal pump capacity and discharge performance.
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 method eliminates radial displacement, extends bearing service life, maintains discharge performance, and simplifies the manufacturing process by enabling accurate fusion without positioning members, thus enhancing production efficiency and reducing costs.
Implementation Method 1
providing small vibrations while applying an appropriate pressurizing force between the front plate and the impeller blade having the base plate attached thereto; melting the sharp-pointed ridge-like protrusions
Data Source
AI summary
The present invention provides a method for manufacturing a closed impeller that has a simple configuration and enables fusion in a very accurate position. The method includes: forming a frustum-shaped front plate and a disk-shaped base plate formed therebelow, upper surfaces of a plurality of unit impeller blade plates made from a synthetic resin extending in radial directions which are formed as impeller blade tip surfaces, with sharp-pointed ridge-like protrusions having an acute upper end and a width less than a width of the impeller blade tip surface being integrally formed on the impeller blade tip surfaces. In the method, an inner surface of the front plate and the plurality of impeller blade tip surfaces are formed as parts of conical surfaces and formed so that the cone apex angles of the two conical surfaces are equal to each other. Then, the front plate is placed on the impeller blade and the ends of the sharp-pointed ridge-like protrusions and the inner surface of the front plate are brought into contact with each other. Small vibrations are then provided while applying an appropriate pressurizing force between the front plate and the impeller blade having the base plate attached thereto, the sharp-pointed ridge-like protrusions are melted, and the front plate is fused to the tip surfaces of the impeller blade.