Automotive Vacuum Vane Pump Composite Rotor Design
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Solution Overview
Problem
Existing automotive vacuum vane pumps face issues with vibrations due to high centrifugal forces, leading to high energy consumption and mechanical wear, as well as vane tip and pump chamber wall abrasion, particularly in designs using single-material vanes or complex, cost-intensive fiber-reinforced thermosetting plastic vanes.
Innovation Solution
The use of a radially moveable rotor vane comprising a metal vane body made from an aluminum alloy with axial or radial recesses for weight reduction and stability, combined with separate thermosetting plastic vane tips that are more elastic and less hard than the pump chamber wall, providing reduced abrasion and improved air-tightness through form-fitted connections and longitudinal movability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a metal vane is used, then stability is improved, but centrifugal forces increase causing vibrations and high energy consumption
Solution Approach 1:
The vane is constructed as a composite component with a metal vane body providing structural stability and fiber-reinforced plastic tips providing lightweight properties and reduced centrifugal forces. This composite structure resolves the contradiction by combining materials with complementary characteristics.
Solution Approach 2:
The vane is divided into two functional segments: a metal vane body for structural support and stability, and separate plastic tips for lightweight operation and reduced centrifugal effects. This segmentation allows each part to optimize its properties independently.
2Stability of the object's composition
If a metal vane is used, then stability is improved, but mechanical wear and abrasion increase
Solution Approach 1:
The combination of metal and fiber-reinforced plastic creates a composite vane where the plastic tips provide wear-resistant properties while the metal body provides stability, resolving the contradiction between stability and wear resistance.
Solution Approach 2:
Different parts of the vane have different material properties optimized for their specific functions: the metal body provides structural stability while the plastic tips provide wear resistance and elasticity for reliable operation.
3Reliability
If fiber reinforced thermosetting plastic vanes are used, then abrasion is reduced, but manufacturing complexity and cost increase
Solution Approach 1:
The vane is segmented into a metal body and separate plastic tips, allowing each component to be manufactured independently using suitable processes, then assembled. This reduces overall manufacturing complexity compared to creating a fully integrated fiber-reinforced plastic vane.
Solution Approach 2:
The composite construction with metal body and plastic tips provides abrasion resistance comparable to fully plastic vanes while simplifying manufacturing through independent component production and assembly.
4Reliability
If vane tips are made softer than pump chamber wall, then abrasion of chamber wall is reduced, but vane tip wear increases
Solution Approach 1:
The softer plastic vane tips are designed as sacrificial components that wear preferentially, protecting the expensive pump chamber wall. The tips can be replaced independently when worn, extending the overall system life while maintaining chamber wall integrity.
Solution Approach 2:
The plastic vane tips act as an intermediary material between the metal vane body and the pump chamber wall, providing a softer contact surface that reduces chamber wall abrasion while being replaceable to maintain vane functionality.
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 configuration enhances the long-term functionality and air-tightness of the pump by minimizing abrasion and energy consumption, while maintaining structural integrity and reducing the impact of centrifugal forces at high rotating speeds.
Implementation Method 1
The plastic tips can have a hardness which is less than the pump chamber wall hardness. Therefore, the abrasion of the metal pump chamber wall can be reduced significantly.
Implementation Method 2
A vacuum vane pump with a relatively heavy metal vane tends to vibrations due to high centrifugal forces
Data Source
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AI summary
The invention refers to an automotive vacuum vane pump (10), comprises a housing (40) with a radially moveable rotor vane (20), wherein the vane (20) consists of at least two components, i.e. a vane body (22) and one or two vane tips (24) at the end of the vane, The vane (20) abuts a pump chamber wall (44), separating the pump chamber (44) in an intake room (45) and a pressure room (46).