Hybrid Lubrication Ring for Compact Pipe Expander Lubricant Channels
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Solution Overview
Problem
Conventional manufacturing methods for lubrication rings in mechanical expanders face challenges with small pipe diameters, such as 14 inches or less, due to limited installation space, making it difficult to position and manufacture fluid bores, leading to complex and risky manufacturing processes with high scrap rates.
Innovation Solution
A hybrid lubrication ring combining conventional and additive manufacturing, where a steel ring is manufactured conventionally and then enhanced with additive manufacturing to create high-strength parts with compact fluid channels and circumferential common rails for efficient lubricant distribution, reducing component height and the number of seals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional manufacturing methods are used for lubrication rings with small pipe diameters (14 inches or less), then the installation space is limited, but the manufacturing complexity increases and scrap rate becomes high
Solution Approach 1:
The patent applies additive manufacturing (3D printing) technology to manufacture the lubrication ring, transitioning from conventional subtractive or formative methods to a layer-by-layer deposition process. This enables complex internal fluid bore structures to be created without the spatial constraints that limit conventional drilling and machining methods, particularly for small diameter pipes where installation space is limited.
Solution Approach 2:
The patent changes the manufacturing parameters by adopting additive manufacturing processes with metal powder and laser fusion, allowing for precise control of material deposition and complex geometry creation. This enables the fabrication of lubrication rings with optimized internal channel structures that would be impossible or extremely difficult to achieve with conventional manufacturing methods.
2Ease of manufacture
If conventional manufacturing methods are used for lubrication rings, then the manufacturing process is simple, but the positioning and manufacturing of fluid bores becomes difficult and risky
Solution Approach 1:
Additive manufacturing enables the creation of three-dimensional fluid bore structures with precise positioning that cannot be achieved through conventional drilling methods. The layer-by-layer construction allows for accurate placement of bores in complex spatial arrangements, eliminating the limitations of two-plane drilling and ensuring precise fluid distribution channel positioning.
Solution Approach 2:
The manufacturing process parameters are fundamentally changed by using additive manufacturing with controlled metal powder deposition and laser fusion. This provides precise control over material placement and bore geometry, ensuring consistent positioning accuracy and reducing manufacturing variability and scrap rates associated with conventional methods.
3Ease of manufacture
If additive manufacturing is used for the lubrication ring, then the manufacturing is simplified and reproducible, but the component dimensions need to be reduced for pipes up to 14 inches
Solution Approach 1:
Additive manufacturing enables precise control over component dimensions and material properties. The process parameters (layer thickness, powder particle size, laser power, scanning speed) can be optimized to produce lubrication rings with exact dimensional specifications required for pipes up to 14 inches, ensuring reproducibility and consistency across production batches.
Solution Approach 2:
The patent utilizes metal powder materials in the additive manufacturing process, allowing for the creation of lubrication rings with optimized material properties and density. The controlled deposition and fusion of metal powder enables the production of components with tailored mechanical properties suitable for the specific dimensional requirements of smaller pipe applications.
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 approach simplifies and reproducibly manufactures lubrication rings, reducing component size, assembly effort, and leakage points, while ensuring precise lubricant distribution and reducing the need for special seals, making it suitable for both new and existing systems.
Implementation Method 1
Application of metal powder layers and fusing with the aid of a laser on the blank
Data Source
AI summary
A lubrication ring for a mechanical expander (1) for sizing large pipes comprises a conventionally manufactured ring (12) made of steel, in particular construction steel. Fluid bores are provided in the ring (12). A part (13) of the lubrication ring (6) is manufactured by an additive manufacturing technology.