Sheet Metal Housing Welding for Hydrodynamic Couplings
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Solution Overview
Problem
Existing hydrodynamic coupling designs in turbine compound systems face challenges in cost-effectively and securely mounting sheet metal housings without causing heat-induced distortion or material changes in the pump wheel during welding, especially when the housing diameter is smaller than the pump wheel.
Innovation Solution
A sheet metal housing for hydrodynamic machines is constructed from at least two individual sheet metal components that are aligned and welded together, with a recess at the joint abutment area open towards the joint to prevent heat input, allowing the edges to protrude over the recess and avoiding direct contact with the wheel during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the housing is welded directly to the pump wheel, then secure mounting is achieved, but heat input causes distortion and material changes in the pump wheel
Solution Approach 1:
The drive gear serves as an intermediary component between the housing and the pump wheel. The housing is welded to the drive gear instead of directly to the pump wheel, thereby mediating the thermal impact and preventing heat-induced distortion and material changes in the pump wheel while maintaining secure mounting.
Solution Approach 2:
The mounting connection is segmented into two separate welding joints: one between the housing and the drive gear, and another between the drive gear and the pump wheel. This segmentation isolates the thermal influence to specific localized areas away from the pump wheel's critical regions, preventing harmful heat propagation.
2Ease of manufacture
If the housing is designed as a single deep-drawn component, then manufacturing is simplified, but additional shaping after assembly is required and heat input during welding causes distortion
Solution Approach 1:
The housing is divided into multiple separate sheet metal components that are assembled and welded together. This segmentation allows each component to be manufactured independently with standard sheet metal forming processes, avoiding the need for complex deep-drawing and post-assembly shaping, while the welding is performed on the drive gear rather than the pump wheel, preserving dimensional accuracy.
3Volume of moving object
If the housing diameter is smaller than the pump wheel diameter, then compact design is achieved, but direct welding to the pump wheel is not feasible
Solution Approach 1:
The drive gear acts as a mediator that bridges the size mismatch between the compact housing and the larger pump wheel. The housing can be welded to the drive gear's hub or flange area, which provides sufficient welding surface area even when the housing diameter is smaller than the pump wheel diameter, making the mounting feasible without direct contact with the pump wheel.
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 allows for secure, cost-effective mounting of sheet metal housings in hydrodynamic couplings, preventing undesirable heat input and material changes, ensuring reliable operation and durability.
Implementation Method 1
In order to avoid an undesirable heat input into the primary wheel or respectively the secondary wheel, it is equipped with a recess in the area of the joint abutment which is open toward the location of the joint and which progresses along the joint abutment
Implementation Method 2
the two sheet metal parts are first appropriately aligned on the primary wheel and/or the secondary wheel and are accordingly placed side by side, either to be in immediate contact with each other, or at a predetermined small distance from each other. Subsequently the two sheet metal components are welded to each other on the primary wheel and/or the secondary wheel
Implementation Method 3
hydrodynamic machines, such as hydrodynamic couplings, include hydrodynamic retarders, and also hydrodynamic converters include a primary wheel and a secondary wheel which together form a work space which is filled or can be filled with operating medium and in which through driving the primary wheel an operating medium circulation is caused which transfers torque or respectively power to the secondary wheel
Data Source
AI summary
A hydrodynamic machine, and especially a hydrodynamic coupling, for a turbine compound system includes (a) a bladed primary wheel and a bladed secondary wheel which together form an operating space which is filled or can be filled with operating medium, and (b) a housing which encloses the primary wheel and the secondary wheel and which is manufactured from sheet metal. The housing is manufactured from at least two separate sheet metal components which are placed on the primary wheel and/or the secondary wheel, are aligned with each other at a joint abutment location, and are welded together. In the area of the welded joint abutment, a relief which is open toward the joint abutment is provided and which extends along the joint abutment in the surface of the primary wheel and/or the secondary wheel.