Impeller Blade Slot Assembly for High-Speed Chiller Strength
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Solution Overview
Problem
Conventional impeller manufacturing methods for chillers are costly, difficult to inspect, and challenging to apply to high-speed rotating components, with limited structural strength and quality control.
Innovation Solution
An impeller design featuring blades with protrusions coupled to grooves in a shroud and hub, formed using sheet metal processing and numerical control processing, with a heat treatment process to minimize deformation, and a circular rib on the shroud for enhanced strength, and welding for secure coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a brazing method is used to manufacture the impeller, then all components can be formed by NC processing, but the manufacturing cost becomes high and adhesion inspection is limited
Solution Approach 1:
The impeller is divided into three separate components: a hub, a shroud, and multiple blades. These components are manufactured using different methods optimized for each part's requirements, then assembled together. This segmentation allows the hub and shroud to be NC-processed with high precision while blades can be made by cost-effective sheet metal processing, resolving the contradiction between manufacturing precision and cost.
Solution Approach 2:
The patent combines multiple manufacturing methods (NC processing for hub and shroud, sheet metal processing for blades) within a single impeller assembly. By merging these different manufacturing approaches, the invention achieves both high precision where needed (hub/shroud) and cost effectiveness (blades), resolving the technical contradiction.
2Ease of manufacture
If a casting method is used to manufacture the impeller, then production is simplified, but it is impossible to check the shape of flow path and performance quality
Solution Approach 1:
By segmenting the impeller into separately manufactured components (hub, shroud, blades), the invention enables precise control and inspection of each component's geometry, particularly the flow path shapes in the hub and shroud. This contrasts with casting where the entire impeller is formed as one piece making inspection difficult.
Solution Approach 2:
The hub and shroud are pre-formed by NC processing with precise flow path geometries before assembly. This preliminary precision manufacturing allows for inspection and verification of flow path shapes before final assembly, resolving the quality inspection issue while maintaining production efficiency.
3Ease of manufacture
If a rivet fastening method is used to assemble the impeller, then assembly is straightforward, but it is difficult to apply to the impeller rotating at high speed
Solution Approach 1:
The patent replaces mechanical fastening methods (rivets) with a welding-based joining system. The blades are welded to the hub and shroud, creating a more robust connection capable of withstanding high-speed rotation forces while maintaining assembly feasibility through standardized welding procedures.
4Device complexity
If conventional assembly methods are used, then manufacturing process is simple, but structural strength is insufficient
Solution Approach 1:
The invention introduces intermediate coupling structures: protrusions on the blades that fit into corresponding grooves in the hub and shroud, and circular ribs on the shroud that provide additional coupling points. These intermediaries enhance the mechanical interlocking and structural strength while maintaining a relatively simple assembly process.
Solution Approach 2:
The impeller uses composite construction combining different materials and joining methods: NC-processed metal components (hub and shroud) joined with welded and mechanically coupled blade assemblies. This composite approach achieves high structural strength while keeping the overall assembly process manageable.
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 design increases structural strength, reduces manufacturing costs, facilitates easy inspection and assembly, and minimizes deformation, resulting in a more durable and efficient impeller for chiller systems.
Implementation Method 1
performing a heat treatment process on the shroud, blade and hub that are provisionally coupled
Implementation Method 2
welding for secure coupling
Data Source
AI summary
The present disclosure relates to an impeller and a method of manufacturing the same. The impeller includes: a hub in which a plurality of spiral first slots are formed; a shroud which is positioned opposite the hub, and has a plurality of spiral second slots formed therein; and a plurality of blades which is coupled to the hub and the shroud, and have an upper protrusion formed on one side and a lower protrusion formed on the other side; and wherein the upper protrusion is inserted into and coupled to a second hole formed in the second slot, and the lower protrusion is inserted into and coupled to a first hole formed in the first slot.