Impeller Wear Ring Removal Tool Design
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Solution Overview
Problem
Current methods for removing impeller wear rings are inefficient, often requiring significant manual effort and breaking the wear ring into pieces, which is time-consuming and labor-intensive.
Innovation Solution
A tool comprising a base, spreader disc, legs with saw tooth ends, spreader bolts, and a puller bolt is used to insert into the wear ring channel, tighten the spreader bolts to engage the legs with the wear ring, and then use the puller bolt to remove the wear ring from the impeller housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a screw driver or chisel like tool is used to remove the wear ring, then the wear ring can be removed, but the wear ring is broken into pieces and significant manual effort is required
Solution Approach 1:
The tool is divided into multiple functional components: a base, spreader bolts for engaging the wear ring, and a puller bolt for extraction. This segmentation allows each component to perform its specific function efficiently, avoiding the need for manual chipping while enabling complete wear ring removal without breaking.
Solution Approach 2:
The spreader bolts act as intermediaries between the puller bolt and the wear ring. By first engaging the wear ring with the spreader bolts and then applying gradual pull force through the puller bolt, the tool enables controlled extraction without requiring excessive manual force or risking breakage.
2Productivity
If manual chipping methods are used, then the wear ring can be removed, but significant man hours are consumed
Solution Approach 1:
The manual chipping process is replaced with a mechanical extraction system. The tool uses threaded bolts and a pulley mechanism to apply controlled force, transforming the removal process from manual chipping to mechanical extraction, thereby significantly reducing the time and effort required.
Solution Approach 2:
The tool allows for dynamic adjustment of force application through the threaded bolts. The spreader bolts can be tightened to engage the wear ring, and the puller bolt can be gradually tightened to extract it, enabling a controlled and efficient removal process that minimizes time consumption.
3Ease of operation
If the wear ring is broken into pieces, then it can be removed, but the replacement process becomes more complex
Solution Approach 1:
The tool converts the potential harm of wear ring breakage into a benefit by designing a extraction mechanism that applies gradual, controlled force. The puller bolt and spreader bolts work together to extract the wear ring intact, eliminating the need for piece-by-piece reassembly and simplifying the replacement 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
The tool allows for efficient and complete removal of the wear ring without breaking, reducing man-hours and ensuring a smooth replacement process, maintaining motor efficiency.
Implementation Method 1
tightening a plurality of spreader bolts causing a spreader to engage the legs with the wear ring
Implementation Method 2
tightening a puller bolt, the puller bolt passing through the spreader and engaging an impeller
Implementation Method 3
a plurality of legs comprising: a first end coupled to the leg base, and a saw tooth shaped end
Data Source
AI summary
Described herein is a tool for removing a wear ring, the tool comprising: a base; a leg base; a spreader disc comprising: a top, bottom, and sloped edge; a plurality of legs comprising: a first end coupled to the leg base, and a saw tooth shaped end; a plurality of spreader bolts, passing though the base and threaded into the spreader disc; and a puller bolt, passing through the base and spreader disc; and threaded into the leg base.