Universal Pump Housing Machining for Variable Gear Thickness
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Solution Overview
Problem
Conventional gear pumps for dialysis machines require separate machining of different pump housing sections for varying gear thicknesses, leading to high material waste, complex processing, and increased assembly effort, which is costly and inefficient.
Innovation Solution
A universal pump housing blank is produced through primary forming, allowing for minimal machining to create customized pump housing sections that accommodate gears of different thicknesses, reducing material waste and assembly steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate pump housing sections are machined from individual round steel pieces for each gear pump variant, then each pump can be precisely manufactured to its specific performance requirements, but material waste increases, processing complexity increases, and manufacturing cost increases
Solution Approach 1:
A single universal pump housing section is designed to accommodate multiple gear pump variants with different performance requirements. The universal housing contains a receiving pocket that can be selectively deepened by machining to receive gears of different thicknesses, allowing one housing to serve multiple pump configurations (degassing pump, dialysis fluid inlet pump, outlet pump) without requiring separate housings for each variant.
Solution Approach 2:
The pump housing is divided into functional zones: a common universal base structure and a variable receiving pocket depth region. This segmentation allows the majority of the housing to be standardized while only the specific receiving pocket area requires customization through selective machining, reducing overall processing complexity and material waste.
2Manufacturing precision
If separate pump housing sections are machined from individual round steel pieces for each gear pump variant, then each pump can be precisely manufactured to its specific performance requirements, but device complexity and assembly effort increase
Solution Approach 1:
A single universal pump housing section is designed to accommodate multiple gear pump variants with different performance requirements. The universal housing contains a receiving pocket that can be selectively deepened by machining to receive gears of different thicknesses, allowing one housing to serve multiple pump configurations (degassing pump, dialysis fluid inlet pump, outlet pump) without requiring separate housings for each variant.
Solution Approach 2:
The universal pump housing section is pre-designed with a receiving pocket at a standard depth suitable for thinner gears. For pumps requiring thicker gears (like the degassing pump), the receiving pocket is deepened by machining in a preliminary step before gear installation. This preliminary action simplifies subsequent assembly and reduces the need for complex custom machining for each variant.
3Ease of manufacture
If different gear thicknesses are compensated for using spacer rings or sealing plates, then the pump housing can remain the same, but manual assembly effort increases significantly
Solution Approach 1:
The need for separate spacer rings or sealing plates is eliminated by directly integrating the depth compensation into the pump housing structure itself. The receiving pocket depth is selectively increased by machining the housing material directly, removing the intermediary spacer components and their associated assembly steps, thereby reducing manual assembly effort while maintaining housing standardization.
4Productivity
If thicker gears are used for the degassing pump to achieve higher flow rate, then the gear pocket must be deeper, but this requires a different pump housing section
Solution Approach 1:
A single universal pump housing section is designed to accommodate multiple gear pump variants with different performance requirements. The universal housing contains a receiving pocket that can be selectively deepened by machining to receive gears of different thicknesses, allowing one housing to serve multiple pump configurations (degassing pump, dialysis fluid inlet pump, outlet pump) without requiring separate housings for each variant.
Solution Approach 2:
The receiving pocket depth parameter is selectively modified by machining to accommodate different gear thicknesses. For the degassing pump requiring higher flow rate and thicker gears, the receiving pocket depth is increased. This parameter change is achieved through selective machining of the universal housing, maintaining standardization while adapting to different performance requirements.
Data Source
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AI summary
Method for manufacturing pumps (1) of different capacities for use in a blood treatment device, preferably a dialysis machine, with a pump housing or pump housing section (4) for the bearing-mounted reception of a fluid conveying device (16, 18), preferably two gears in mesh engagement, comprising the following steps: primary forming of a universal pump housing blank (38) with all the features common to the different pumps (1) and with such oversizes that machining is permitted to manufacture all the different pumps (1) from the same primary formed pump housing blank (38); and individualizing the universal pump housing blank (38) by machining in the area of the oversizes to achieve the respective capacity.