To improve the hydraulic performance in an ultra-low specific speed magnetic drive pump, optimized design of impeller based on orthogonal test was carried out. Blades number Z, bias angle in peripheral direction of splitter blades θ_s, inlet diameter of splitter blades D_si, and deflection angle of splitter blades α were selected as the main factors in orthogonal test. The credibility of the numerical simulation was verified by prototype experiments. Two optimized impellers were designed through the analysis of orthogonal test data. The internal flow field, pressure fluctuation, and radial force were analyzed and compared between optimized impellers and original impeller. The results reveal that impeller 7 (Z = 5, θ_s = 0.4θ, D_si = 0.75D₂, α = 0°) could increase the head and efficiency, compared to the original impeller, by 2.68% and 4.82%, respectively. Impeller 10 (Z = 5, θ_s = 0.4θ, D_si = 0.55D₂, α = 0°) reduced the head by 0.33% and increased the efficiency by 8.24%. At design flow rate condition, the internal flow of impeller 10 was the most stable. Peak-to-peak values of pressure fluctuation at the volute tongues of impeller 7 and impeller 10 were smaller than those of the original impeller at different flow rate conditions (0.6 Q_d, 1.0 Q_d and 1.5 Q_d). Radial force distribution of impeller 10 was the most uniform, and the radial force variance of impeller 10 was the smallest.

Based on the shear stress transport (SST) turbulence model, the influence of different outlet pipe angles on the head and efficiency of a boiler circulating pump was analyzed. When the outlet pipe angle changed from 115° to 130°, the head and efficiency of the pump reduced significantly. The boiler circulating pump with 115° outlet pipe angle was selected as the further research object, and the reliability of the numerical simulation was verified by experiments. The transient flow of the prototype pump under the design flow rate condition (1.0Q_d) and four other flow rate conditions (0.6Q_d, 0.8Q_d, 1.2Q_d, and 1.4Q_d) was studied. The results show that, under the conditions of design flow and large flow rate (1.0Q_d, 1.2Q_d, and 1.4Q_d), the centrality and regularity of radial force distribution are obviously better than those of small flow rate (0.6Q_d, 0.8Q_d). The leakage of the rear seal ring is less than that of the front seal ring under five flow rate conditions. As the flow rate increases, the leakage of front and rear seal rings decreases, and the leakage ratio of front and rear seal rings increases. The energy loss of the rear cover plate is greater than the energy loss of the front cover plate under five flow rate conditions. With the increase in flow rate, the total loss energy of the prototype pump decreases first and then increases, and the energy loss of the disc becomes larger and larger.

The model pump is a high-speed, high-power pump designed to achieve rapid mine flooding rescue. This study conducted experiments to investigate pump performance curves, including head, efficiency, and power for the following six different rotation speeds: 3000, 3600, 4200, 4800, 5400, and 6000 rpm. Then, the numerical simulation method based on computational fluid dynamics commercial code Ansys was used to present the internal flow of the pump for the six different rotation speeds through steady and unsteady analyses. Results show that the numerical results agree well with experimental data. The designs of outlet and inlet angles of the impeller match each other well at high rotation speeds. The pressure pulsation coefficient C_p in the impeller and the diffuser channel remain constant at the same monitor point under different rotation speed conditions. The varying trend of the pressure-augmented coefficient ΔP indicates that, with the increase in rotation speed, the effect on pressure rise induced by the back part of the impeller channel is more evident than that by the front part. Also, the main frequency components of ΔP are concentrated on the region with low frequency. Moreover, the rotation speed has no significant effect on ΔP in the diffuser region. This study provides effective guidance and valuable reference for the design of high-speed, high-power pumps.

A high-speed magnetic pump rated at 7800 r/min was studied. A numerical model was established, and a hydraulic, vibration, and noise testing system was set up to conduct flow simulations, noise, and vibration experiments at different speeds. The results show that increasing speed leads to a higher pressure difference between the pump chamber and the cooling circuit. Meanwhile, the turbulent kinetic energy at the impeller outlet increases. Despite an increase in energy loss, the loss ratio decreases, and overall efficiency improves. The internal flow noise collected by the outlet hydrophone mainly comes from Rotor–Stator Interference (RSI), and it can sensitively capture changes in rotational speed. The dominant frequency of the outlet noise agrees well with the blade frequency calculated from the set speed, with a maximum deviation of 0.26%. As the speed increases, the overall sound pressure level (OASPL) at the inlet and outlet and the Root Mean Square (RMS) acceleration values at the outlet and pump body generally increase, while the acceleration at the motor base shows a decreasing trend. The conclusions are helpful for the design and optimization of rotary machinery such as high-speed magnetic pumps.