Centrifugal Compressors are the turbomachines also known as turbo-compressors, and belong to the roto-dynamic class of compressors. In these compressors the required pressure rise takes place due to the continuous conversion of angular momentum imparted to the working fluid by a high-speed impeller into pressure. These compressors are used in small gas-turbines, turbochargers, chiller units, in the process and paper industries, oil & gas industries and others.
The design and manufacturing of such compressors are always challenging because of its 3-dimensional shapes, high rotational speeds that interact with different loss mechanisms, and stringent working environments. In many circumstances, it is necessary to analyze an existing compressor, with the end goal being to redesign it, enhance its performance, or to use it in completely different applications. In order to meet such requirements, reverse engineering is a viable option. With reverse engineering, one can review competitor’s design to remain in market competition.
Reverse engineering allows us to collect incomplete or non-existing design data and manufacture an accurate recreation, safely, of the original product or component.
Sometimes, it is also referred to as back engineering, in which centrifugal compressors or any other product are deconstructed to extract design information from them. Oftentimes, reverse engineering involves deconstructing individual components like the impeller or diffuser of larger compressors. End-users often use this approach when purchasing a replacement impeller or any other compressor part from an OEM is not an option. In some cases, where older impellers that have not been manufactured for 20 years or more, the original 2D drawings are no longer available. When this is the case, the only way to obtain the design of an original compressor is through reverse engineering.
Reverse engineering requires a series of steps to gather precise information on a product’s dimensions. Once collected, the data can be stored in digital archives. Figure 1 (left) shows the typical process of reverse engineering. In figure 1 (right), one can see the scanning process of the centrifugal impeller using a laser scanner.
To reverse engineer an impeller or any other part of compressor, an organization will typically acquire the component and take it apart to examine its internal mechanisms. This way, engineers can unveil information about the original design and construction of the product. One can start by analyzing the dimensions and attributes of the impeller and make measurements of the blade widths, diameters and angles, as these dimensions often relate to the compressor’s performance. Read More