Open Impeller Winglet Design for Abrasive Pump Wear Reduction
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Solution Overview
Problem
Existing submergible pumps used in mining, tunneling, and construction sites face efficiency and wear issues due to abrasive materials like sand and stone, leading to rapid blade wear and increased power consumption, as the differential pressure across the impeller blades causes jet-flow and increased gap distance between the blade and wear plate.
Innovation Solution
An open impeller design with winglets located radially outside an inner radius and extending to the trailing edge, increasing the gap width only where differential pressure is highest, minimizing cross-flow and wear while maintaining efficient flow area and reducing power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the gap between the lower edge of the blade and the wear plate is reduced to increase pumping efficiency, then the pumping performance is improved, but the blade wear increases rapidly due to jet-flow of abrasive matter
Solution Approach 1:
The patent applies local quality by providing wear protection only at the trailing edge region of the blade where the lower edge faces the wear plate, rather than protecting the entire blade. The wear-resistant element is positioned specifically at the location subjected to jet-flow of abrasive matter, creating a localized protective zone that addresses the wear problem without affecting overall blade performance or requiring full-blade protection.
2Duration of action of stationary object
If winglets are added to the blade to reduce wear, then the blade lifespan is extended, but the device complexity increases
Solution Approach 1:
The wear-resistant element is designed as a separate, detachable component that can be independently positioned and removed, rather than being an integrated part of the blade structure. This segmentation allows the wear protection function to be added without permanently complicating the impeller design, and the modular element can be replaced independently when worn.
Solution Approach 2:
The wear-resistant element functions as a sacrificial component designed to wear away over time while protecting the main blade. This disposable element can be easily replaced when worn, extending the overall impeller lifespan without requiring complex redesigns or replacements of the entire impeller assembly.
3Reliability
If the winglet extends from the leading edge to the trailing edge of the blade, then the wear protection is maximized, but the flow area of the impeller channels is reduced
Solution Approach 1:
The wear-resistant element is positioned only at the trailing edge region of the blade where the lower edge faces the wear plate, rather than extending along the entire blade length. This localized placement provides wear protection exactly where jet-flow of abrasive matter occurs, while preserving the flow area and hydraulic performance of the impeller channels in other regions.
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 prolongs the lifespan of impellers by 30-50% by reducing wear and maintaining efficiency, as the winglet placement minimizes power consumption and extends the need for replacement, while adapting to varying differential pressures across different impeller sizes.
Implementation Method 1
there is a pressure difference between the suction side (radially inner side) of the blade and the pressure side (radially outer side) of the blade
Implementation Method 2
The pressure difference over the blade, or differential pressure across the lower edge gap, results in a jet-flow of media, i.e. liquid and abrasive matter, from the pressure side to the suction side through the narrow gap between the lower edge of the blade and the wear plate
Implementation Method 3
The jet-flow of pumped media through the gap will wear down the lower edge of the blade
Data Source
AI summary
An open impeller for a submergible pump for pumping abrasive fluids. The impeller has a cover plate, a hub and at least two spirally swept blades, each blade having a leading edge, a trailing edge, and a lower edge extending from the leading edge to the trailing edge and separating the suction and pressure sides of the blade. At least one blade includes a winglet at the lower edge projecting from the suction side, located radially outside an inner radius of the impeller, and extending circumferentially to the trailing edge at the suction side at a maximum radius of the impeller. The lower edge and winglet lower wear surface are configured to be located opposite of and facing a pump wear plate. The inner radius is equal to the largest of the maximum radius of the impeller multiplied by 0.6, and an inlet radius of the impeller multiplied by 1.2.