Liquid Pump Impeller Welding for Standard Sonotrode Assembly
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Solution Overview
Problem
Existing impeller manufacturing methods for liquid pumps require shaped sonotrodes for different sizes, leading to high acquisition, setup, and manufacturing costs, and laser welding systems are expensive.
Innovation Solution
An impeller design with a cover plate and base body, featuring integrally formed pump vanes and a central receptacle for an impeller bearing bush, connected via welding, allowing for use of a standard sonotrode and enabling easy coding of an ultrasonic system, and utilizing thermoplastic materials for uniform welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If shaped sonotrodes are used for different impeller sizes in ultrasonic welding, then welding can be performed for various sizes, but acquisition, setup and manufacturing costs increase
Solution Approach 1:
The patent applies universality by designing a standardized sonotrode interface on the base body that allows a single sonotrode to weld impellers of different sizes. The base body incorporates a standardized welding surface with consistent geometry and material properties, enabling one sonotrode to effectively weld various impeller configurations without requiring size-specific shaped sonotrodes, thereby reducing costs while maintaining versatility
2Device complexity
If integrally formed pump vanes are used on the cover plate, then manufacturing complexity is reduced, but welding uniformity must be maintained
Solution Approach 1:
The patent applies local quality by creating intentional variations in the base body structure at the welding interface. The base body incorporates localized features such as reinforced welding surfaces, optimized material distribution, and geometric configurations specifically at the welding zone to ensure uniform welding results, while the rest of the structure maintains integral pump vane design for reduced manufacturing complexity
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
Reduces manufacturing costs by allowing a single sonotrode to be used for different sizes, facilitates quick component holder changes, and ensures efficient, uniform welding with reduced setup costs.
Implementation Method 1
the cover plate (2) is connected to the base body (3) via at least one pump vane (5) by means of a welding process
Implementation Method 2
utilizing thermoplastic materials for uniform welding
Implementation Method 3
a sonotrode can be used in ultrasonic welding in such a way that no shaped sonotrode is required
Data Source
AI summary
An impeller for a liquid pump with a cover plate and a base body. An intake channel is arranged on the cover plate. A plurality of pump vanes are formed integrally with the cover plate. The base body has a receptacle for an impeller bearing bush in a central region. A cover plate is connected to the base body via at least one pump vane by means of a welding process.