Shrouded Impeller Self-Alignment via Integrated Features
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Solution Overview
Problem
Current methods for manufacturing shrouded impellers face challenges in achieving precise concentric and spatial alignment of components without external alignment tools and effective joining processes, leading to instability and complexity in production.
Innovation Solution
The method involves machining components with alignment features such as circumferential steps and legs that allow for accurate concentric and spatial alignment, followed by the introduction of a filler material into a gap between the components, which is then fused to join them securely, using conventional tools and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If components are assembled using alignment apparatus or jigs, then alignment precision is improved, but device complexity and manual labor requirements increase
Solution Approach 1:
The patent extracts the alignment function from external jigs and apparatuses and integrates it directly into the impeller components themselves. Alignment features such as circumferential steps, positioning pins, and mating surfaces are built into the blade component and shroud component, eliminating the need for separate alignment tools while maintaining high alignment precision during assembly
Solution Approach 2:
The components perform their own alignment function through self-contained alignment features. The blade component's circumferential step and the shroud component's positioning features automatically align the parts concentrically and spatially when brought together, without requiring external alignment apparatus or manual adjustment
2Strength
If components are joined by conventional welding or tacking, then joining strength is improved, but alignment precision and fluid flow quality deteriorate
Solution Approach 1:
The patent performs alignment before joining by providing pre-formed alignment features (circumferential steps, positioning pins, mating surfaces) that establish precise concentric and spatial alignment of components prior to the joining process. This preliminary alignment ensures that when components are joined, their relative positions are already optimized, eliminating the need for post-joining alignment adjustments that would compromise precision
Solution Approach 2:
The patent extracts the alignment function from the joining process itself and separates it into distinct alignment features that are built into the components. This allows alignment to be achieved independently of the joining method, enabling the use of simple joining techniques without sacrificing alignment precision or creating interference with fluid flow
3Reliability
If integrated unitary impellers are manufactured, then reliability is improved by eliminating welds and seams, but manufacturing complexity and cost increase
Solution Approach 1:
The patent divides the impeller into separate blade component and shroud component that can be manufactured independently using simpler processes, then joined together to form an integrated unitary structure. This segmentation allows each component to be manufactured with appropriate techniques for its specific geometry and material requirements, avoiding the need for complex specialized tools needed for complete unitary manufacturing
Solution Approach 2:
The patent merges the separately manufactured blade component and shroud component into a single integrated impeller assembly through precise joining at the interface. The alignment features ensure that when joined, the components form a unified structure that behaves like a unitary impeller, eliminating welds and seams in the final assembled product while maintaining structural reliability
4Manufacturing precision
If manual adjustment within jigs is used, then alignment precision is improved, but productivity decreases
Solution Approach 1:
The alignment features built into the components enable self-alignment during assembly, eliminating the need for skilled manual adjustment operations. The circumferential steps, positioning pins, and mating surfaces automatically guide the components into correct concentric and spatial alignment when brought together, making the process suitable for automation and significantly improving manufacturing throughput
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 enables robust, scalable, and automatable production of shrouded impellers with high precision alignment and stable assembly, reducing manufacturing complexity and improving durability.
Implementation Method 1
A gap is defined between the blade component and the shroud component. Filler material is introduced into the gap (e.g., by capillary action).
Data Source
AI summary
Multipart shrouded impellers and methods for manufacturing multi-part shrouded impellers are described. Components of the shrouded impeller include alignment features that, when brought into contact, provide concentric and spatial alignment of the component parts. Upon alignment a gap remains between portions of the components, which permits the introduction of a filler material that joins the components into a unitized whole.