Hybrid Guide Device for Centrifugal Pump Efficiency

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Solution Overview

Problem

Multi-stage centrifugal pumps, particularly boiler feed pumps, face efficiency limitations due to non-optimized solid guide devices that cause flow separation and vortex buildup, making them economically inefficient.

Innovation Solution

A hybrid guide device is constructed using generatively manufactured components, such as those produced by selective laser melting or buildup welding, combined with conventionally manufactured parts, to create a filigree and hydraulically optimized geometry that minimizes flow separation and vortex buildup, enhancing pump efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If solid guide devices are used in multi-stage centrifugal pumps, then structural strength is ensured, but flow separation and vortex buildup occur, reducing pump efficiency

Engineering Contradiction:

Improvepump efficiencyVSAvoidflow separation and vortex buildup

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The guide device employs a porous or lattice structure instead of a solid construction. This porous structure reduces flow separation and vortex buildup while maintaining sufficient mechanical strength through strategic material distribution, thereby improving pump efficiency without compromising structural integrity

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The guide device is constructed using composite materials or hybrid manufacturing approaches combining conventionally manufactured and generatively manufactured parts. This allows optimization of both flow characteristics and structural strength, resolving the contradiction between efficiency and harmful flow patterns

Inventive Principle:

Principle #40Composite materials

2Reliability

If generatively manufactured guide devices are used, then flow optimization and efficiency are improved, but manufacturing complexity and production costs increase

Engineering Contradiction:

Improvepump efficiencyVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The guide device is divided into multiple components: conventionally manufactured parts for structural elements and generatively manufactured parts for flow-optimized guide vanes. This segmentation allows each part to be manufactured using the most suitable process, balancing efficiency improvements with manufacturing simplicity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention merges conventionally manufactured and generatively manufactured components into a single guide device assembly. This combination approach integrates the structural reliability of conventional manufacturing with the flow optimization of additive manufacturing, while simplifying production through modular assembly

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If solid guide devices are used, then manufacturing simplicity is maintained, but pump efficiency is limited and economic impact increases

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidpump efficiency

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The guide device transitions from solid construction to porous or lattice structures, fundamentally changing the geometric parameters while maintaining manufacturability. This parameter change enables flow optimization that significantly improves pump efficiency without requiring complex manufacturing processes

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If conventional guide devices are used, then production costs are controlled, but flow separation causes energy losses and reduced efficiency

Engineering Contradiction:

Improveproduction costVSAvoidenergy losses from flow separation

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The porous or lattice structure of the guide device reduces flow separation and vortex buildup, minimizing energy losses while maintaining cost-effective production. The optimized flow paths reduce turbulence and recirculation, directly addressing energy loss issues without significantly increasing manufacturing cost

Inventive Principle:

Principle #31Porous materials

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

The hybrid guide device achieves higher efficiency by preventing flow separation and vortex buildup, reducing component mass, and allowing for larger dimensions and more complex geometries not achievable with conventional methods, while simplifying assembly and reducing production costs.

Implementation Method 1

The guide element deflects the flow of the preceding impeller virtually without losses to the following impeller

Methodology Applied

Scientific EffectFluid flow guidance:

Implementation Method 2

Flow separation is largely to be prevented, and retardation with the lowest possible losses is to be ensured

Methodology Applied

Scientific EffectFlow separation prevention: Flow Separation

Data Source

PatentUS20240151243A1Hybrid Manufacture of an Impeller

Publication Date: 2024.05.09 KSB SE & CO KGAA

AI summary

A centrifugal pump includes at least one impeller. Downstream of the impeller there is arranged a guide device. The guide device is a hybrid component that includes at least one conventionally manufactured constituent and at least one generatively manufactured constituent.