Hybrid Pump Guide Vanes for Low-Loss Stage Casing Flow
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing centrifugal pumps, particularly multi-stage high-pressure pumps, face limitations in efficiency due to robust and poorly flow-optimized guide vane designs, leading to significant deceleration losses and inefficiencies, especially in continuous operations like boiler feed pumps, while conventional manufacturing methods struggle to achieve hydraulically optimized geometries and large dimensions.
Innovation Solution
The guide device of the centrifugal pump is constructed as a hybrid component, combining conventionally manufactured parts with additively manufactured guide elements, utilizing processes like selective laser melting and cladding to create delicate, flow-optimized geometries with thin profiles and precise connections, reducing swirl and preventing flow separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a stage casing is manufactured using conventional subtractive machining methods, then manufacturing precision can be achieved, but material waste is excessive and productivity is low
Solution Approach 1:
The patent changes the manufacturing parameter from subtractive machining to additive manufacturing (3D printing), fundamentally altering the material removal approach. This enables near-net-shape manufacturing where material is deposited layer-by-layer to form the final geometry, reducing material waste while maintaining precision through controlled deposition processes and post-manufacturing heat treatment
Solution Approach 2:
The patent incorporates preliminary design of the manufacturing process that accounts for both additive fabrication and subsequent heat treatment in a single integrated workflow. The stage casing is designed with features that optimize both 3D printing and heat treatment processes, achieving high precision through pre-planned thermal processing that corrects any dimensional deviations from the additive manufacturing step
2Manufacturing precision
If a stage casing is manufactured using conventional subtractive machining methods, then manufacturing precision can be achieved, but productivity is low
Solution Approach 1:
The patent transitions from subtractive machining to additive manufacturing, changing the fundamental manufacturing parameter. Additive manufacturing builds parts layer-by-layer, significantly reducing manufacturing time compared to conventional machining that requires multiple setup operations, tool changes, and sequential material removal steps, thereby improving productivity while maintaining precision through controlled deposition and post-processing heat treatment
Solution Approach 2:
The patent implements preliminary integration of the heat treatment process into the manufacturing workflow. By pre-planning and immediately following additive manufacturing with heat treatment in a single continuous process, the patent eliminates intermediate handling, repositioning, and setup time, thereby improving overall productivity while ensuring manufacturing precision through controlled thermal processing
3Productivity
If a stage casing is manufactured using additive manufacturing alone, then productivity is improved and material waste is reduced, but manufacturing precision is insufficient
Solution Approach 1:
The patent implements continuous manufacturing by immediately performing heat treatment on the additive manufactured stage casing without intermediate handling or storage. This continuous process ensures that the part undergoes controlled thermal processing while still in the manufacturing sequence, achieving high manufacturing precision by eliminating dimensional changes that would occur during separate handling and storage operations
Solution Approach 2:
The patent applies heat treatment as a post-processing parameter change to the additive manufactured part. This thermal processing modifies the microstructure and dimensional stability of the plastic material, achieving the required manufacturing precision that additive manufacturing alone cannot provide, while maintaining the productivity benefits of the additive manufacturing process
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 hybrid design achieves enhanced hydraulic efficiency, minimizes deceleration losses, and simplifies assembly, while allowing customization and cost-effective production, making it suitable for high-pressure applications.
Implementation Method 1
The stage casing (10) is additively manufactured in a hybrid process
Implementation Method 2
The hybrid process continues with a heat treatment process
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a centrifugal pump (1) having an impeller (5, 9) which is surrounded by a casing (22). The casing (22) comprises at least one guide element (23). The guide element (23) is designed as a hybrid component that consists of at least one conventionally manufactured component and at least one generatively manufactured component.