Stamped Impeller Reinforcement for Lightweight Torque Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing centrifugal pump impellers are costly, weight-intensive, and involve complex production processes with external suppliers, often requiring welding and multiple materials, which increases production time and risks.
Innovation Solution
The impeller design features a front plate and back plate connected by radial blades, with a reinforcement portion formed by folding and flattening excess metal sheet material to create a single, strong, lightweight component that reduces material thickness and weight while enhancing mechanical strength, eliminating the need for welding and external hubs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcement elements are welded in the area assigned to stress transmission, then the necessary thickness of material is reached in localized portions, but production costs increase and production time increases
Solution Approach 1:
The reinforcement element is formed as an integral part of the basic disk during the stamping process itself, before assembly. The stamping operation creates a localized thickening in the stress transmission area, eliminating the need for separate welding operations and reducing production costs while maintaining the necessary material thickness for strength
Solution Approach 2:
The reinforcement element and basic disk are merged into a single integrated component. The reinforcement element is formed directly from the basic disk material through stamping, combining what would have been separate welded parts into one piece, thereby eliminating welding operations and reducing production complexity
2Strength
If reinforcement elements are welded in the area assigned to stress transmission, then the necessary thickness of material is reached in localized portions, but production time increases
Solution Approach 1:
The reinforcement element is formed during the initial stamping operation of the basic disk, before assembly takes place. This preliminary formation of the reinforcement element eliminates subsequent welding steps, directly reducing production time while ensuring the necessary material thickness is achieved in the stress transmission area
3Strength
If the basic disk is formed with augmented thickness to withstand stresses, then torque transmission capability is improved, but the overall weight of the impeller increases
Solution Approach 1:
The reinforcement element creates a localized thickening only in the specific area of the basic disk where stress transmission occurs. This localized reinforcement provides the necessary torque transmission capability without increasing the thickness and weight of the entire impeller, maintaining lightweight design while ensuring structural strength where needed
4Adaptability or versatility
If multiple materials and external suppliers are involved, then specific functional requirements are met, but production costs increase and supply risks increase
Solution Approach 1:
The reinforcement element and basic disk are combined into a single integrated component formed from one material. This merging eliminates the need for multiple materials and external suppliers for separate parts, reducing production costs and supply chain risks while still meeting the functional requirements through the integrated design
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 production costs and weight, ensures necessary mechanical characteristics, and simplifies the manufacturing process by using a single material code and avoiding welding, while increasing mechanical strength and reducing torque transmission pressure.
Implementation Method 1
a single piece of stamped, bent and flattened metal sheet
Data Source
AI summary
An impeller, particularly for centrifugal pumps, including a front plate and a back plate arranged coaxially to a central axis of the impeller and rigidly connected to each other by a plurality of radial blades which are angularly distributed about the central axis; the front plate has a central through opening adapted to connect the impeller to a driving shaft; the impeller includes a reinforcement portion that extends perimetrically to the through opening, at least partially surmounting the front plate; the front plate and the reinforcement portion are constituted by a single part formed by stamping, bending and flattening a metal sheet.