Modular Gear Pump Expansion for Higher Flow Without Piping Changes
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Solution Overview
Problem
Gear pumps have practical limits on displacement volume due to gear size and number of teeth, requiring system reconfiguration for increased flow rates, which is inefficient and disruptive.
Innovation Solution
A modular expansion kit for gear pumps that includes a case extension, elongated gears, and shafts, allowing for increased volumetric displacement without altering connection points or piping systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the gear diameter and number of teeth are increased to increase displacement volume, then the flow rate capacity is improved, but the pump size and system complexity increase
Solution Approach 1:
The pump is divided into a base pump unit and a modular expansion assembly that can be added to increase displacement volume. The expansion assembly includes additional gear sections and casing segments that attach to the base unit, allowing flow rate increases without redesigning the entire pump.
Solution Approach 2:
Instead of increasing gear diameter (two-dimensional expansion), the invention extends the pump axially (third dimension) by adding expansion sections with additional gears. This increases displacement volume while maintaining a compact footprint and avoiding system reconfiguration.
2Productivity
If the gear length along the axis is increased to increase displacement volume, then the flow rate capacity is improved, but the pump becomes more complex and harder to manufacture
Solution Approach 1:
The axial extension is achieved by segmenting the pump into modular sections (base unit and expansion assembly). Each section contains complete gear sets and casing segments that can be manufactured independently using standard processes, then assembled together to achieve the desired total displacement volume.
Solution Approach 2:
The pump design allows dynamic configuration where expansion sections can be added or removed based on required flow rates. This modular approach simplifies manufacturing by using repeated standard sections rather than custom-long gears, while still achieving variable displacement volumes.
3Productivity
If a larger pump is installed to increase flow rate, then the displacement volume is improved, but system reconfiguration and piping changes are required
Solution Approach 1:
The expansion assembly is designed to attach to standard pump interfaces and maintain compatibility with existing mounting flanges, drive shafts, and coupling mechanisms. This universality allows the pump to be upgraded in-place without modifying piping systems or reconfiguring the overall system layout.
Solution Approach 2:
The expansion assembly contains complete pump functionality (gears, casing, seals) nested within an attachment structure that interfaces with the base pump. This nested design allows the expansion to be added as a self-contained unit that integrates with existing connections, avoiding system reconfiguration.
Data Source
Figure 1A~1B
Figure 2
Figure 3~4
AI summary
A modular expansion assembly for a gear pump is provided. The modular expansion assembly includes a case extension, a set of elongated replacement gears, and a set of elongated replacement shafts. The case extension is removably attached between a main case of the gear pump and a faceplate assembly of the gear pump. The case extension includes a second chamber that aligns with a first chamber of the main case to form a continuous combined chamber. The set of replacement gears is configured to extend axially the substantial length of the continuous combined chamber, and the set of replacement shafts is configured to extend through the continuous combined chamber into bores of the faceplate assembly and bores of a backplate assembly of the gear pump. When installed on a gear pump, the modular expansion assembly allows for increased volumetric displacement without requiring changes to connecting piping systems.