Segmented Francis Runner Assembly for External Weld Access
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Hydraulic machines, such as Francis-type turbines, face challenges due to large dimensions, high manufacturing costs, transportation difficulties, and health and safety issues related to welding and grinding operations, particularly in the assembly of runners which require skilled labor and are time-consuming to produce.
Innovation Solution
A Francis-type runner is designed as a plurality of segments with integrally formed band, crown, and blade portions, allowing for assembly without welding near high-stress areas, using narrow gap welding techniques and robotic tools to join segments externally, reducing health risks and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a runner is made as a single large cast or welded piece, then structural strength is improved, but manufacturing time and cost increase significantly
Solution Approach 1:
The runner is divided into multiple segments that can be manufactured separately and assembled together. Each segment can be produced independently using conventional casting or welding processes, significantly reducing manufacturing time and cost while maintaining structural integrity through proper joining methods at the segment interfaces.
2Strength
If a runner is made as a single large piece, then structural integrity is improved, but transportation difficulty increases
Solution Approach 1:
The runner is divided into multiple segments that can be manufactured and transported separately to the installation site. This segmentation allows each segment to be sized for convenient transportation while maintaining structural integrity through proper joining methods at the segment interfaces, eliminating the need to transport a single large piece.
3Ease of operation
If welding operations are performed in confined sections of hydraulic passages, then assembly flexibility is improved, but health and safety risks increase
Solution Approach 1:
The runner is segmented such that joining edges are positioned on external surfaces rather than in confined internal passages. This allows welding and assembly operations to be performed from the outside, improving worker safety and health conditions while maintaining assembly flexibility through proper design of the segment interfaces.
4Ease of manufacture
If a runner is designed with multiple segments, then transportation and manufacturing ease are improved, but the complexity of assembly increases
Solution Approach 1:
The runner is divided into segments with simplified joining edges that can be positioned on external surfaces, allowing for straightforward assembly operations. The segmentation provides transportation and manufacturing benefits while the design of joining edges minimizes assembly complexity through proper geometric configuration and accessibility.
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 reduces manufacturing time and costs, simplifies transportation, and enhances safety by avoiding high-stress area welding, resulting in a stronger and more efficient runner assembly process.
Implementation Method 1
using narrow gap welding techniques and robotic tools to join segments externally
Data Source
AI summary
A runner for a hydraulic machine comprising a band, a crown, a plurality of blades extending between the crown and the band, wherein the runner comprises a plurality of runner segments which together define the runner, each runner segment comprising a band portion, a crown portion and a blade, which portions are integrally formed with one another, each runner segment being attachable to another segment at a band joining edge and a crown joining edge, wherein the band joining edge and the crown joining edge are each spaced apart from the blade of the segment.