This section will provide the generation ideas and methods for industrial centrifugal pump linkage driven by DT technology.
4.1. The Idea of Linked Generation for Industrial Centrifugal Pumps Driven by DT
The digital industrial pump design scheme is a method that utilizes modern digital technologies, particularly DT technology, Internet of Things (IoT) technology, and Artificial Intelligence (AI) technology, to optimize and automate the design process. As shown in
Figure 4, the scheme is as follows:
(1). Requirement Stage: Utilizing data analysis techniques, such as the data processing module encapsulated in
Appendix A, allows for the acquisition and understanding of user requirements, as well as the definition of design objectives and requirements.
(2). Design Stage: Use CAD and physical modelling tools to create a detailed DT model of the industrial pump. The model should include all key physical characteristics, such as material properties, structural features, and operating conditions.
(3). Simulation Stage: Employ computer simulation tools to perform dynamic simulation and analysis of the DT model, predicting pump performance and identifying potential optimization points.
(4). Optimization Stage: Leverage AI and machine learning technologies to automatically optimize design schemes based on a large amount of historical data and design knowledge, thereby enhancing design quality and efficiency.
(5). Verification Stage: Implement optimized design schemes into actual pumps for testing and verification. Then, feed test results back into the DT model for further design optimization.
(6). Production Stage: Utilize DT technology to simulate and optimize the production process, improving production efficiency and quality.
In summary, this approach not only enhances design efficiency and quality but also improves product performance and reliability. The impeller design software is key to achieving rapid design in this context.
4.2. Interactive Rapid Generation Method for Key Components
Engineers only need to follow the design modules within the software to swiftly, accurately, and efficiently generate a hydrodynamically sound three-dimensional impeller, as well as axial projection diagrams and two-dimensional engineering drawings of the wooden mold, through the software above.
Based on the above analysis, the importance of providing designers with visual interactive tools lies in making the design process more intuitive, understandable, and participatory. Such tools can visually display each step and result of the design, helping designers better understand and master the entire design process, allowing quicker and more effective modifications and optimizations. Simultaneously, using interactive tools can enhance the sense of design participation and real-time feedback, further improving design accuracy and quality while reducing error rates.
Therefore, according to the analysis, the impeller design software comprises eight modules: global design, parameter setting, shaft plan, blade setting, streamline design, blade thickening, blade chamfering, and data output. The contents it needs to include are:
(1). Initial Parameter Setting: Engineers input parameters such as flow rate, head, and rotation speed, select the medium type and pump type, and the software will calculate specific speed, shaft power, efficiency, NPSH (Net Positive Suction Head), hydraulic efficiency, and volumetric efficiency.
(2). Impeller Parameter Design: Engineers can set various impeller parameters, such as material density, blade type, rotation direction, and design coefficients, such as impeller hub diameter and impeller outlet diameter. The software will calculate critical parameters of the impeller based on the input, such as hub diameter, inlet diameter, impeller diameter, outlet width, etc.
(3). Blade Axial View Design: Engineers can design the axial view of the blade, and the software will calculate and update the related curves and parameters in real-time.
(4). Blade Design: Engineers determine the number of blades and, streamline numbers and design various parameters of the blade. The software will calculate various speed parameters of the blade and draw the velocity triangle.
(5). Streamline Design: Engineers can design the streamline by adjusting the interface and streamline angle. The software will calculate in real-time and provide a front view of the impeller streamline for reference.
(6). Blade Thickening: Engineers can set the blade thickness and thickening method, and the software will calculate and draw the thickening line based on the design data.
(7). Blade Chamfer Design: Engineers can design the chamfer of the blade, and the software will redraw the coordinate axis based on the design data, read the parameters of the Bezier curve, and draw the chamfer diagram.
(8). Projection Diagram and 3D Blade Export: After completing the impeller parameter design, engineers can choose to export the engineering diagram and data. The software will launch Solidworks and use a large number of macro commands, combined with the parameter set saved to the global variables in the previous seven steps, to quickly draw the axial projection diagram, the wooden mold diagram, and the 3D blade.
In response to this, we propose a DT-driven rapid interactive generation method. The following summarizes the steps implemented by the blade software, and the pseudocode to realize this function is shown in Algorithm 1. Here, ‘H’ represents the design head of the centrifugal pump, ‘Q’ represents the design flow rate, and ‘n’ represents the design rotational speed. ‘cal_globalparameter_impeller’ is the packaged module for calculating the basic parameters of the centrifugal pump. ‘cal_Basicparameter_impeller’ calculates the basic parameters of the impeller. ‘Drawoutline’ generates the coordinates of the impeller curve point set. ‘Blade_design’ computes the blade profile parameters. ‘DrawThickness’ calculates the coordinates of the blade thickening points. ‘CalChamferData’ is used for calculating the coordinates of the impeller chamfer. ‘Anycad’ is the external call program that displays the 3D blade preview. Lastly, ‘CalChamferData’ connects to SolidWorks to draw 3D models and 2D engineering drawings.
(1). Basic parameters are inputted into the global parameter module, and the system calls the design and calculation modules to solve for efficiency and other related parameters. The results are displayed on the software interface.
(2). The system stores the basic parameter information in the global information module and proceeds to the impeller parameter setting module. Here, the system calls the parameter setting and calculation modules to solve for the impeller parameters and generate an initial axial view. Engineers can adjust design parameters in real-time.
(3). After completing the basic impeller parameter settings, the system enters the axial view module. The design and calculation modules are called again to generate an axial projection and related performance curve diagrams. Engineers can adjust the axial view in real-time and the related data will be displayed on the interface and saved in the global information module.
(4). Upon entering the blade design interface, engineers can adjust various parameters. The system calls the design and calculation modules to generate an axial view and streamline the angle calculation table and parameters for the front and back cover plates. This also results in the real-time generation of an axial streamline diagram and velocity triangle interactive interface.
(5). After confirming the axial projection, the system enters the streamlined design module. Here, engineers can adjust the blade streamline and the design and calculation modules are called to generate a streamline development diagram and streamline angle change diagram.
(6). Once the streamline module design is complete, the system enters the blade thickening module. The design and calculation modules are called to generate an axial view after blade thickening and a three-dimensional hydraulic model of the blade.
(7). By entering the blade chamfering module, engineers can design the chamfer, and the system calls the design and calculation modules to generate real-time interactive graphics of the chamfer.
(8). Finally, the system enters the data output module, calling all the design and calculation modules to generate a three-dimensional hydraulic model and projection diagram of the impeller. These are output as specified files.
Algorithm 1: Impeller generation algorithm |
Input: Q, H, n
Output: 3D models and 2D engineering drawings
Begin
Set Q, H, n While The performance curve and preview model meet the design requirement , P, η, ← cal_globalparameter_impeller (Q, H, n) Basic parameter:, , , , ← cal_Basicparameter_impeller (Q, H, n) Performance curve point set1 ← Drawoutline (Basicparameter) Number and Placement angle ← Blade_design (point set, Basic parameter) Blade Thickening Dot Set2 ← DrawThickness (Basic parameter, Placement angle, Z) Fillet point set3 ← CalChamferData (Basic parameter, Placement angle, Z) Preview 3D blade ← Anycad (All point sets) Generate 3D models and 2D engineering drawings ← CalChamferData (All point sets)
End |
4.3. Collaborative Generation Method for Related Components
Based on the above analysis, this system needs to work in conjunction with the front-end design modules to form a linked generation method. The required system functions include:
(1). Parameter setting module: At this stage, designers input the parameters for the global design and load the preset blade parameters into the software. The software then calculates the basic parameters of the volute, such as the base circle diameter ‘’ and the volute inlet width ‘’, based on these inputs. It also recommends ranges for these parameters. Designers have the option to input custom parameters for the design.
(2). Volute cross-section design module: In this stage, the designer selects the type of flow path and the cross-section shape (e.g., rectangular, trapezoidal, or circular). The designer then specifies parameters for the eighth section, such as the height of the trapezoid, the left and right angles, the upper fillet radius, and the arc radius. The software calculates the parameters for each section based on the cross-sectional area curve chosen by the designer (e.g., a linear spline variation curve or a straight line) and displays the graphical changes in real-time.
(3). Volute diffuser design module: Here, the designer selects the diffuser type (center exit or eccentric exit) and sets the corresponding parameters. For an eccentric exit diffuser, parameters such as the diffuser diameter ‘’, the length of the diffuser, the distance ‘A’ from the diffuser exit center to the volute center, the tongue placement angle ‘’, the coefficient ‘K’, and the tongue fillet radius ‘r’ need to be configured. For a center exit diffuser, parameters including the diffuser diameter, the length, the tongue fillet radius, and the X and Y values of the Bezier curve midpoint are set.
(4). Generating graphics: After completing the design, the designer can click the ‘confirm parameter’ button, and the software will generate a 2D diagram of the volute based on the calculated results, displaying a preview on the interface. If there are no obvious design errors, proceed to the final step, generating water body diagrams and engineering drawings. By employing macro technology, the software intelligently manipulates SolidWorks to quickly and accurately draw 3D water body diagrams and 2D engineering diagrams of the volute based on datasets computed by algorithms.
(5). Parameter setting: After designing the impeller, the user enters the volute parameter setting interface. Upon invoking the impeller design values, the parameter design module and the Lagrange calculation module are used, calling the ‘Cal’ method to calculate the recommended, minimum, and maximum values for ‘’ and ‘’. This process determines the volute speed coefficient ‘’ and the area of the eighth section.
(6). Volute cross-section design: The designer selects the flow path type and cross-section shape on the volute cross-section setting interface and finalizes the parameters for the VIII section. The software leverages multiple design modules and calculation methods, including the global information module, cross-section design module, and matrix operation module, to compute the parameters and coordinates for each section and to draw the section projection diagram.
(8). Diffusion section design: With the volute cross-section parameters established, the designer accesses the diffusion section design interface. There are two diffusion section types: eccentric exit and center exit. The software calculates all coordinates based on the parameters entered by the engineer, invokes the diffuser design module, polar coordinate conversion module, etc., and provides a projection diagram preview.
(9). Data output: Upon completing the above designs, the engineer enters the data output module. The engineer configures the data options, and the software utilizes the volute data output, volute parameter setting, and other modules to automatically generate the three-dimensional model and two-dimensional engineering drawings of the volute.
The pseudocode for this function is shown as Algorithm 2, where ‘H’ represents the designed head of the centrifugal pump, ‘Q’ represents the designed flow rate, ‘n’ represents the designed rotational speed, ‘’ represents the outlet diameter of the diffuser, ‘L’ represents the length of the diffuser, and ‘r’ represents the fillet radius of the tongue.
The ‘
cal_globalparameter_Volute’ function represents the encapsulated module for calculating the basic parameters of the volute. ‘
CalEveryoneH’ is the module for calculating parameters such as the height of the volute cross-section. ‘
Calhelix’ calculates the coordinate parameters of the volute spiral line point set. ‘
CalDiffusionsection’ is responsible for computing the parameters of the volute diffusion section. ‘
Edrawing’ refers to the externally called program that displays the 2D engineering drawing of the volute. Lastly, ‘
CalChamferData’ is the module that utilizes all previous calculation data to interface with SolidWorks for drawing 3D models and 2D engineering drawings.
Algorithm 2: Volute generation algorithm |
Input: Q, H, n, , L, r
Output: Begin
, b2 While preview model meet the design requirements Basic parameter ← cal_globalparameter_Volute (Q, H, n, , b2) Section point set1 ← CalEveryoneH (Basicparameter) Spiral point set2 ← Calhelix (Section point set1, Basic parameter) Diffusion segment point set3 ← CalDiffusionsection (, L, r) Preview 2D engineering drawing← Edrawing (All point sets) Generate 3D models and 2D engineering drawings ← CalChamferData (All point sets)
End |