Impeller Vane Structure for Projection-Welded Pump Assembly

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Solution Overview

Problem

The manufacturing of impellers with three-dimensionally shaped vanes using pressed metal plates is hindered by the inability to use spot welding due to vane inclination, leading to increased costs and reduced productivity with laser welding.

Innovation Solution

The impeller design incorporates a two-dimensional portion parallel to the rotation axis, fixed to the main plate and side plate using projection welding, with the three-dimensional portion optionally joined by laser spot welding to prevent deformation during assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If spot welding is used to fix the vane to the main plate, then the manufacturing cost is reduced and productivity is improved, but the vane cannot be properly joined because it is inclined with respect to the normal direction of the main plate

Engineering Contradiction:

Improvemass productivity of impellersVSAvoidwelding feasibility

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The vane is divided into two distinct portions: a three-dimensional portion that provides the required fluid dynamic shape, and a two-dimensional portion that serves as a welding surface. This segmentation allows the vane to maintain its functional three-dimensional shape while providing a flat surface for spot welding, thereby resolving the contradiction between welding feasibility and productivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The two-dimensional portion acts as an intermediary element between the three-dimensional vane and the main plate. It provides a flat welding surface that facilitates spot welding while being integrally connected to the three-dimensional portion, thus enabling both easy manufacture and high productivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If laser welding is used to fix the three-dimensional vane to the main plate, then the vane can be joined without pressing, but the welding time and manufacturing costs increase

Engineering Contradiction:

Improvewelding feasibility for inclined surfacesVSAvoidwelding time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

By segmenting the vane into three-dimensional and two-dimensional portions, the invention enables the use of faster spot welding on the two-dimensional portion, eliminating the need for time-consuming laser welding while maintaining welding feasibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the geometric parameters of the vane by adding a two-dimensional portion with a flat surface, which transforms the welding problem from an inclined surface (requiring laser welding) to a flat surface (suitable for spot welding), thereby reducing welding time and cost.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If a three-dimensional vane shape is used to achieve ideal pump performance, then fluid flow efficiency is improved, but spot welding cannot be applied due to the inclined surface

Engineering Contradiction:

Improvepump performanceVSAvoidwelding method applicability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The vane is segmented into a three-dimensional portion that ensures ideal pump performance through optimized fluid flow shape, and a two-dimensional portion that enables spot welding. This segmentation allows both high reliability in pump performance and ease of manufacture through spot welding to be achieved simultaneously.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the vane are given different geometric qualities: the three-dimensional portion has the complex shape required for optimal fluid flow, while the two-dimensional portion has a flat surface optimized for welding. This local differentiation resolves the contradiction between performance requirements and manufacturing ease.

Inventive Principle:

Principle #3Local quality

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 approach allows for cost-effective and efficient manufacturing of impellers with improved mass productivity by avoiding vane tilting and bending during welding, reducing production time and costs.

Implementation Method 1

the two-dimensional portion is fixed to the main plate by a first weld formed by projection welding

Methodology Applied

Scientific EffectProjection welding: Welding

Implementation Method 2

a part of the three-dimensional portion is joined to the main plate by laser spot welding

Methodology Applied

Scientific EffectLaser spot welding: Laser Beam Welding

Data Source

PatentUS11788543B2Impeller, pump having the impeller, and method of producing the impeller

Publication Date: 2023.10.17 EBARA CORP

AI summary

The impeller (1) includes a main plate (3) formed from a metal plate; and vanes (5) each formed from a metal plate. Each of the vanes (5) has a three-dimensional portion (5A) having a surface inclined with respect to a rotation axis (CA) of the impeller (1) and a two-dimensional portion (5B) having a surface parallel to the rotation axis (CA) of the impeller (1), and the two-dimensional portion (5B) is fixed to the main plate (3) by a first weld (10) formed by projection welding.