Segmented Impeller Assembly for Faster Compressor Manufacturing
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Solution Overview
Problem
Existing methods for manufacturing centrifugal compressor impellers are time-consuming, prone to defects, and difficult to achieve high quality and reliability due to complex geometries and material limitations, especially in the assembly of complex flow passages.
Innovation Solution
The impeller is manufactured by segmenting into single blade, body, and shroud sections, which are then joined using additive manufacturing and mechanical locking systems like dovetail joints, allowing for faster production and improved quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the impeller is manufactured as a single solid piece using full milling or EDM, then the structural integrity and reliability are improved, but the production time and manufacturing complexity increase significantly
Solution Approach 1:
The impeller is divided into multiple sector segments (typically 3-5 segments around the circumference), each containing a portion of the blades and corresponding flow passage sections. These segments are manufactured separately using simpler processes and then joined together using mechanical locking systems or welding, significantly reducing the overall production time while maintaining structural integrity through proper joint design
2Ease of manufacture
If traditional welding is used to join impeller components, then the manufacturing flexibility is improved, but the risk of welding defects, cracking, and thermal distortion increases
Solution Approach 1:
The impeller is segmented into multiple sections that can be joined by mechanical locking systems (such as dovetail joints, tongue-and-groove connections, or interference fits) rather than welding. This eliminates the thermal effects and defect risks associated with welding while maintaining manufacturing flexibility through modular assembly
Solution Approach 2:
Joining elements or intermediate components (such as locking rings, keys, or mechanical interlocks) are introduced to connect the impeller segments. These intermediaries facilitate reliable joining without requiring welding, thereby avoiding welding defects, cracking, and thermal distortion while preserving ease of manufacture
3Manufacturing precision
If complex shaped tools and electrodes are used for EDM machining, then the manufacturing precision of complex flow passages is improved, but the device complexity and production time increase
Solution Approach 1:
The complex flow passages are formed separately in each impeller segment using simpler, more accessible machining operations. The segmentation allows each tool or electrode to work on a smaller, more accessible portion of the flow passage, reducing the complexity of the tools required while maintaining the overall geometric accuracy of the complete impeller assembly
Solution Approach 2:
The flow passage geometry is preliminarily formed in each segment during the segment manufacturing process using accessible machining operations. This preliminary action allows for better tool accessibility and simpler tooling compared to attempting to machine the complete complex geometry in a single piece, while the final assembly maintains the required overall precision
Data Source
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AI summary
The invention refers to a new manufacturing technique for impellers (100) for centrifugal rotating machine. The impeller (100) is made by composition of single vanes pieces that fit to the hub or directly to the rotor shaft by welding, friction welding or mechanical locking system. The manufacturability of the segments (100') is easy fast and cheap and make it possible to use advanced manufacturing technologies like additive manufacturing of the type of Direct Metal Laser Melting.