Multi-stage Impeller via Additive Manufacturing
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Solution Overview
Problem
Conventional pump designs face limitations in pressure generation and efficiency, with axial pumps being limited in pressure capability, radial impellers producing low flow with lower efficiency, and complex multi-stage designs being costly and difficult to manufacture.
Innovation Solution
A multi-stage pump impeller design integrated into the motor shaft using additive manufacturing, featuring a two-part axial flow shaft with static and rotating components, allowing for efficient pressure generation without fluid flow direction changes and reduced part count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If multiple axial impeller stages are arranged in series to generate higher pressure, then pressure generation capability is improved, but device complexity increases due to multiple rotating and stationary vane sets
Solution Approach 1:
The patent merges multiple impeller stages into a single integrated impeller structure where multiple impeller vanes are arranged at different radial positions on the same rotating element. This allows multiple pumping stages to be combined in one rotating component rather than requiring separate rotating and stationary vane sets for each stage, thereby reducing device complexity while maintaining multi-stage pressure generation capability
Solution Approach 2:
The patent implements a nested configuration where impeller vanes are arranged concentrically at different radial positions, with inner vanes nested within the rotational path of outer vanes. This nesting allows multiple impeller stages to occupy the same radial space, reducing the axial length and overall complexity of the pump structure while maintaining the multi-stage pressure generation function
2Stress or pressure
If radial impeller is used to generate significant pressure, then pressure generation is improved, but pumping efficiency decreases due to fluid flow direction change
Solution Approach 1:
The patent applies local quality by designing impeller vanes with different orientations at different radial positions. Inner impeller vanes can have different angles and configurations compared to outer impeller vanes, allowing each vane to be optimized for its specific radial location and flow conditions, thereby maintaining efficient axial flow while generating pressure
3Loss of energy
If axial impeller design is used for high efficiency and high flow rate, then pumping efficiency is improved, but pressure generation capability is limited
Solution Approach 1:
The patent combines multiple axial impeller stages into a single rotating impeller structure, maintaining the efficient axial flow characteristics of axial impellers while achieving multi-stage pressure generation through the concentric arrangement of multiple impeller vanes at different radial positions
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 achieves higher efficiency and pressure generation with a smaller, less complex pump structure, capable of self-priming and internal cooling, and allows for the use of lighter materials and quicker prototyping.
Implementation Method 1
the rotating outer shaft portion having rotating impeller vanes configured inside and coupled to the outer portion to move the fluid axially along the two-part axial flow shaft as the rotating outer shaft portion axially rotates
Implementation Method 2
each stage having a combination of a respective static diffuser vane and a respective rotating impeller vane, so that the respective static diffuser vane converts kinetic energy of the fluid exiting a rotating impeller vane outlet
Data Source
Figure 1~1B
Figure 2~2C
Figure 3
AI summary
A pump features a two-part axial flow shaft having a static inner shaft portion and a rotating outer shaft portion; the static inner shaft portion having static diffuser vanes, and also having two shaft ends configured to affix to a frame of a pump so the static inner shaft portion does not rotate; and the rotating outer shaft portion having an outer portion configured to affix to a rotor of the pump to rotate the rotating outer shaft portion, also having rotating impeller vanes configured inside and coupled to the outer portion to move the fluid axially along the two-part axial flow shaft as the rotating outer shaft portion axially rotates in relation to the static inner shaft portion.