Peristaltic Pump Rocker MIM Manufacturing
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Solution Overview
Problem
Existing peristaltic pumps require complex and costly manufacturing processes due to the need for high dimensional stability and fatigue strength, with manual alignment and additional treatments like anodizing, which increases material usage and assembly complexity.
Innovation Solution
The rocker of the rotor is made from high-strength stainless steel using metal injection molding (MIM), integrating threading aids and tube guides, reducing material usage and manufacturing costs while maintaining strength and chemical resistance, eliminating the need for additional surface treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rockers are manufactured by milling from solid aluminum, then dimensional stability and fatigue strength are achieved, but material usage becomes excessive and manufacturing costs increase
Solution Approach 1:
The patent changes the manufacturing method from subtractive milling to additive SLM (Selective Laser Melting) technology, fundamentally altering the production parameter from material removal to material deposition. This enables near-net-shape manufacturing with material usage exceeding 90%, compared to less than 50% in traditional milling processes
Solution Approach 2:
The patent employs aluminum powder as a consumable raw material that is directly transformed into the final component through SLM. The powder material is fed continuously during the building process, eliminating the need for expensive solid stock and minimizing waste, as unused powder can be recovered and reused
2Strength
If rockers are manufactured by milling from solid aluminum, then strength is achieved, but manufacturing complexity and additional treatments like anodizing increase
Solution Approach 1:
The patent transforms the manufacturing approach from mechanical milling requiring multiple setup operations to SLM additive manufacturing, which builds components layer-by-layer in a single continuous process. The digital model directly controls the laser deposition, eliminating complex fixture arrangements and tool path programming
Solution Approach 2:
The patent extracts the anodizing surface treatment step from the manufacturing process by producing components with the required surface quality directly through SLM. The selective laser melting process inherently creates a fine-grained microstructure with adequate surface finish, eliminating the need for subsequent chemical anodizing operations
3Object-affected harmful factors
If rockers are made from aluminum, then chemical resistance is achieved, but deformation occurs during roller axle crimping
Solution Approach 1:
The patent changes the material parameter from aluminum to aluminum alloy with optimized composition and microstructure through SLM processing. The controlled cooling rates and thermal cycles in SLM create a fine dendritic microstructure with enhanced mechanical properties, achieving both chemical resistance and sufficient strength to prevent deformation during assembly
Solution Approach 2:
The patent utilizes aluminum-based composite materials with controlled microstructure produced by SLM. The process enables incorporation of reinforcement phases and creates a composite microstructure that combines the chemical resistance of aluminum with enhanced mechanical strength and deformation resistance
4Ease of operation
If tube guide elements are integrated into the rocker, then threading operation is simplified, but rocker shape becomes more complex
Solution Approach 1:
The patent merges the tube guide elements with the rocker body into a single integrated component manufactured by SLM. The digital model allows seamless integration of the guide geometry with the rocker structure, eliminating separate assembly operations while the additive process handles the complexity without additional manufacturing difficulty
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 simplifies the manufacturing process, reduces material usage, and enhances the pump's functionality and service life by integrating functions like tube guides and threading aids directly into the rocker, ensuring reliable operation with reduced deformation and assembly costs.
Implementation Method 1
a tube roller pump or peristaltic pump, i.e. a positive-displacement pump, in which the fluid to be pumped is pressed through a tube by external mechanical deformation of the latter
Implementation Method 2
an elastically deformable fluid line disposed between the low-pressure side and the high-pressure side in the form of a tube segment referred to as pump segment is deformed, specifically squeezed, between a support surface of a pump bed and a rotor rotating relative to said support surface and having at least two squeeze elements
Data Source
AI summary
A peristaltic pump, specifically for pumping fluid in an extracorporeal blood treatment apparatus, includes a pump housing that accommodates a rotor rotatable about a rotor axis and a squeeze element. The pump housing includes a support surface extending in a curved shape around the rotor axis and being radially spaced from the rotor. The support surface can support a tube segment that inserted radially between the rotor and support surface. The rotor supports the squeeze element via a rocker mounted on the rotor in a pivotable and cushioned manner. The rocker supports an insertion aid by which the tube segment can be pressed into the pump bed, and tube guide elements by which the tube segment is centrally alignable to the squeeze element. The rocker is made from high-strength stainless steel with high chemical resistance and manufactured by powder injection molding, such as metal injection molding.