Rotary Machine Rotation Part Thermal Bonding
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Solution Overview
Problem
Existing rotary machine components, such as compressors and pumps, face inefficiencies due to gaps between blades and shrouds, which affect the transfer of rotational kinetic energy to fluids, and existing bonding methods like welding can compromise the strength of these components.
Innovation Solution
A rotation part design featuring a base unit with protruding blade units, shroud segment support units, and reinforcing units, where the distance between the blade unit and shroud segment support unit is optimized to prevent thermal effects during bonding, combined with a method involving cutting, grinding, and laser welding processes to enhance strength and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to bond blades and shroud, then the structural strength is improved, but thermal effects during welding compromise the strength of the components
Solution Approach 1:
The shroud is divided into multiple shroud segments that are separately bonded to the blade units. This segmentation allows for controlled bonding processes that minimize thermal effects on any single component while maintaining overall structural strength.
Solution Approach 2:
Reinforcing units are pre-formed at the intersection portions between blade units and shroud segment support units before the bonding process. This preliminary action ensures that the components can withstand thermal effects during welding without compromising strength.
2Loss of energy
If the gap between blades and shroud is reduced to maximize efficiency, then energy transfer is improved, but the structural integrity and strength are compromised
Solution Approach 1:
The shroud is segmented into multiple sections that can be precisely positioned close to the blade units while maintaining structural integrity through the bonding of shroud segments to shroud segment support units.
Solution Approach 2:
The rotation part utilizes composite construction with blade units, shroud segment support units, and reinforcing units formed as integrated or bonded structures, allowing for both strength and reduced gap configuration.
3Strength
If reinforcing units are placed close to blade units to maximize strength, then structural strength is improved, but thermal effects during bonding affect the reinforcing units
Solution Approach 1:
The distance between blade units and reinforcing units is locally optimized at intersection portions. The reinforcing units are positioned at specific distances that provide maximum strength while remaining outside the thermal affectation zone during bonding operations.
4Strength
If complex manufacturing processes are used to enhance strength and minimize thermal effects, then component strength is improved, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into distinct steps: forming base units with blade units, forming shroud segment support units, forming reinforcing units, and bonding shroud segments. This segmentation makes the complex process more manageable and controllable.
Solution Approach 2:
Reinforcing units and shroud segments are prepared in advance before the bonding process. This preliminary preparation simplifies the overall manufacturing process by organizing complex steps into a systematic sequence.
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 optimized design and manufacturing method result in a rotation part with improved strength and efficiency by minimizing thermal effects during bonding, thus maintaining the structural integrity and enhancing the energy transfer capabilities of the rotary machine.
Implementation Method 1
a laser beam is irradiated to the shroud segment and the shroud segment support unit to bond the shroud segment and the shroud segment support unit to each other
Implementation Method 2
an end mill is used to form the base unit, a plurality of blade units protruding from the base unit, and a plurality of shroud segment support units extending in parallel to each other from the blade units
Implementation Method 3
a surface grinder is used to form a plurality of reinforcing units
Data Source
AI summary
There is provided a rotation part of a rotary machine, the rotation part including: a base unit including a surface constituting fluid channels; a plurality of blade units protruding from the base unit; a plurality of shroud segment support units connected to the plurality of blade units and extending in a parallel direction to the surface of the base unit; a shroud segment disposed between and bonded to adjacent shroud segment support units of the plurality of shroud segment support units; and a first reinforcing unit provided on an intersection portion between a blade unit of the plurality of blade units and a shroud segment support unit of the plurality of shroud segment support units, wherein a distance from a protruding direction center line of the blade unit to an end portion of the shroud segment support unit is greater than a maximum distance from the protruding direction center line of the blade unit to an end portion of the first reinforcing unit.