A brushless motor fuel pump with a built-in controller

Abstract

A brushless motor fuel pump with a built-in controller, comprising a control unit, a brushless motor and a fuel pump connected in sequence. The control unit includes an oil outlet cover, a controller, a heat conducting pad, a mounting bracket and a metal heat sink. The mounting bracket is fixedly installed on the upper end of the brushless motor. A circulation cavity for the outflow of oil fluid is provided between the mounting bracket and the upper end of the brushless motor. The circulation cavity, the brushless motor and the fuel pump are connected in sequence. The oil outlet cover is fixedly connected to the upper end of the mounting bracket, and the oil outlet cover is provided with an oil outlet communicating with the circulation cavity. The mounting bracket and the oil outlet cover are hermetically connected to form a sealed cavity for installing the controller. The controller, the heat conducting pad and the metal heat sink are connected in sequence from top to bottom. The lower part of the metal heat sink is hermetically installed in a mounting hole provided in the mounting bracket, and the metal heat sink passes through the mounting hole and is exposed in the circulation cavity.

Description

Technical Field

[0001] The present invention relates to the field of brushless motor fuel pumps, and particularly to a brushless motor fuel pump with a built-in controller. Background Art

[0002] Electric fuel pumps generally adopt a mode in which the controller and the brushless motor are separated. In the prior art, there are also ways to combine the controller and the brushless motor. For example, a built-in controller brushless motor fuel pump disclosed in the application number 2007100713329 specifically includes an oil outlet end cover, an electrical socket, a housing, a pump component, a brushless motor, and a controller. The pump component includes a pump body, a pump impeller, and a pump cover. The brushless motor includes a stator and a winding component, a rotor component, and a Hall sensor. The shaft of the rotor component passes through the pump body and is fixedly connected to the pump impeller. The controller is set as a layered structure with a smaller external dimension that can be placed in the housing. However, there are two problems in actual settings: First, since the controller is a built-in design, there is a technical problem of difficult heat dissipation of the controller; second, the connection relationship between the controller and the brushless motor is relatively close, so the liquid in the brushless motor is likely to penetrate into the cavity where the controller is located, resulting in a malfunction of the controller. Summary of the Invention

[0003] In order to solve the above problems, the present invention provides a brushless motor fuel pump with a built-in controller:

[0004] A brushless motor fuel pump with a built-in controller includes a control unit, a brushless motor, and a fuel pump connected in sequence. The control unit includes an oil outlet cover, a controller, a heat-conducting pad, a mounting bracket, and a metal heat sink.

[0005] The mounting bracket is fixedly installed on the upper end of the brushless motor. A flow cavity for the oil to flow out is provided between the mounting bracket and the upper end of the brushless motor. The flow cavity, the brushless motor, and the fuel pump are connected in sequence. The oil outlet cover is fixedly connected to the upper end of the mounting bracket, and the oil outlet cover is provided with an oil outlet communicating with the flow cavity.

[0006] The mounting bracket and the oil outlet cover are hermetically connected to form a sealed cavity for installing the controller. The controller, the heat-conducting pad, and the metal heat sink are connected in sequence from top to bottom. The lower part of the metal heat sink is hermetically installed in the mounting hole provided in the mounting bracket, and the metal heat sink passes through the mounting hole and is exposed in the flow cavity.

[0007] Preferably, the mounting bracket and the oil outlet cover are hermetically closed to form a box-shaped sealed structure, and a sealing ring is provided at the connection between the mounting bracket and the oil outlet cover. The mounting bracket and the oil outlet cover are hermetically closed, and adding a corresponding sealing ring improves the sealing effect of the sealed cavity. The power components provided on the controller are all arranged on the side close to the heat-conducting pad, and the power components are all in contact with the heat-conducting pad.

[0008] Preferably, the metal heat dissipation plate includes a main board connected to a heat conduction pad and a heat dissipation part protruding downward relative to the main board. The heat dissipation part is hermetically connected to the mounting hole, the lower end of the heat dissipation part is exposed in the circulation cavity, and heat dissipation grooves corresponding to the circulation cavity are provided in the heat dissipation part. The relatively concave setting of the heat dissipation grooves increases the corresponding contact area compared with the planar design, improving the heat dissipation efficiency.

[0009] Preferably, an electrical connection groove and an oil outlet nozzle are provided at the upper end of the oil outlet cover. Electrodes for electrically connecting to a controller are provided in the electrical connection groove. The oil outlet nozzle communicates with the oil outlet, the oil outlet is provided on one side of the oil outlet cover, the oil outlet has a flat axial extension structure, and the oil outlet covers one side of the sealed cavity. The flat structure of the oil outlet and covering one side of the sealed cavity can enable the derived oil liquid to have the largest contact surface with the sealed cavity, thereby further realizing the heat dissipation function of the sealed cavity.

[0010] Preferably, the brushless motor includes a motor housing, a stator, and a rotor. The motor housing is fixedly connected to a control unit. A motor cavity for accommodating the stator and the rotor is provided in the motor housing. The stator is electrically connected to a controller, and the rotor is drivingly connected to a fuel pump.

[0011] Preferably, the rotor includes a rotating shaft and a rotating magnet. The rotating magnet is injection molded on the rotating shaft using plastic magnetic material. A polygonal clamping groove is provided at one end of the rotating magnet. The fuel pump includes a coupling and a pump assembly that are drivingly connected to each other. The coupling is drivingly connected to the polygonal clamping groove.

[0012] Preferably, the rotor further includes an iron core. The iron core is fixedly sleeved on the rotating shaft. The polygonal clamping groove has a hexagonal structure. According to the characteristic that various structures can be formed by plastic magnetic injection molding, an inner concave hexagonal structure that matches the coupling for transmitting torque is made at one end of the rotor magnet. In this way, the rotor magnet not only rotates, but also has the function of transmitting torque through the inner concave hexagonal structure, making the brushless pump structure simpler and more compact.

[0013] Preferably, the fuel pump further includes a filter assembly for filtering fuel.

[0014] Preferably, the brushless motor further includes a motor bracket. The motor bracket is clamped and installed below the mounting bracket. A circulation cavity as described above is provided between the motor bracket and the mounting bracket. One or more circulation ports for communicating the circulation cavity with the motor cavity are provided on the motor bracket.

[0015] Preferably, an annular groove extending circumferentially is provided on the outer surface of the oil outlet cover, and an annular inclined surface is provided at the lower part of the annular groove. The upper part of the motor housing covers the lower part of the oil outlet cover, the mounting bracket and the motor bracket. An annular edge bent obliquely inward is provided at the upper end of the motor housing, and the annular edge and the annular groove form a snap fit. The upper part of the motor housing can effectively prevent the mounting bracket and the motor bracket from being exposed outside, and prevent external contamination from contacting the controller through the gap between the mounting bracket and the motor bracket.

[0016] Beneficial effects: In this application, a sealed cavity for installing the controller is formed by the sealed connection between the mounting bracket and the oil outlet cover, thereby improving the sealing effect of the controller and preventing the infiltration and damage of oil. The heat generated by the components on the controller is taken away by the flowing fuel through the heat-conducting pad and the metal heat sink, realizing the corresponding heat dissipation function. Description of the Drawings

[0017] Figure 1 It is a schematic cross-sectional view of the embodiment.

[0018] Figure 2 It is a three-dimensional cross-sectional view of the embodiment.

[0019] Figure 3 It is a schematic top view of the embodiment.

[0020] Figure 4 It is a cross-sectional structure diagram of the rotating magnet.

[0021] Reference numerals: 1. Oil outlet cover; 2. Controller; 3. Heat-conducting pad; 4. Sealing ring; 5. Mounting bracket; 6. Metal heat sink; 61. Main board; 62. Heat dissipation part; 63. Heat dissipation groove; 7. Motor bracket; 8. Housing; 81. Motor cavity; 82. Annular edge; 9. Stator; 10. Rotor; 101. Rotating shaft; 102. Iron core; 103. Rotating magnet; 11. Pump assembly; 12. Coupling; 13. Filter assembly; 14. Flow cavity; 15. Oil outlet; 16. Sealed cavity; 17. Electrical connection groove; 18. Electrode; 19. Oil nozzle; 20. Polygonal snap groove; 21. Flow port; 22. Annular groove; 23. Annular inclined surface. Detailed Description of the Invention

[0022] The following further describes the present invention in conjunction with Figures 1-4 the embodiments.

[0023] Embodiment: As Figure 1 shown, a brushless motor fuel pump with a built-in controller 2 includes a control unit, a brushless motor and a fuel pump connected in sequence.

[0024] The control unit includes an oil outlet cover 1, a controller 2, a heat conducting pad 3, a mounting bracket 5, and a metal heat sink 6. The controller 2 used in this application is a hall-less controller 2. The mounting bracket 5 is fixedly installed at the upper end of the brushless motor. A flow cavity 14 for oil to flow out is provided between the mounting bracket 5 and the upper end of the brushless motor. The flow cavity 14, the brushless motor, and the fuel pump are connected in sequence. The oil outlet cover 1 is fixedly connected to the upper end of the mounting bracket 5. The oil outlet cover 1 is provided with an oil outlet 15 communicating with the flow cavity 14. The oil outlet 15 is arranged on one side of the oil outlet cover 1. The oil outlet 15 has a flat axial extension structure, and one side of the oil outlet 15 covers a sealing cavity 16. The flat structure of the oil outlet 15 and covering one side of the sealing cavity 16 can enable the derived oil to have the largest contact surface with the sealing cavity 16, thereby further realizing the heat dissipation function of the sealing cavity 16. As Figure 3 shown, an electrical connection slot 17 and an oil outlet nozzle 19 are provided at the upper end of the oil outlet cover 1. An electrode 18 electrically connecting the controller 2 is arranged in the electrical connection slot 17. The oil outlet nozzle 19 communicates with the oil outlet 15.

[0025] The mounting bracket 5 and the oil outlet cover 1 are hermetically connected to form a sealing cavity 16 for installing the controller 2. The controller 2, the heat conducting pad 3, and the metal heat sink 6 are connected in sequence from top to bottom. The lower part of the metal heat sink 6 is hermetically installed in a mounting hole provided in the mounting bracket 5. The metal heat sink 6 passes through the mounting hole and is exposed in the flow cavity 14. The mounting bracket 5 and the oil outlet cover 1 are hermetically covered with each other to form a box-shaped sealing structure. The power components on the controller 2 are all arranged on the side close to the heat conducting pad 3 and are all in contact with the heat conducting pad 3. In this way, the heat generated by the power components can be taken away by the flowing fuel through the heat conducting pad 3 and the metal heat sink 6, thereby protecting the components on the controller 2. A sealing ring 4 is provided at the connection between the mounting bracket 5 and the oil outlet cover 1. The mounting bracket 5 and the oil outlet cover 1 are hermetically covered with each other, and adding the corresponding sealing ring 4 improves the sealing effect of the sealing cavity 16.

[0026] The metal heat sink 6 includes a main board 61 connected to the heat conducting pad 3 and a heat dissipation part 62 protruding downward relative to the main board 61. The heat dissipation part 62 forms a sealed connection with the mounting hole. The lower end of the heat dissipation part 62 is exposed in the flow cavity 14. A heat dissipation groove 63 corresponding to the flow cavity 14 is provided in the heat dissipation part 62. The relatively concave setting of the heat dissipation groove 63 increases the corresponding contact area compared with the planar design and improves the heat dissipation efficiency.

[0027] The brushless motor includes a motor housing 8, a stator 9, a rotor 10, and a motor bracket 7. The motor housing 8 is fixedly connected to the control unit. A motor cavity 81 for accommodating the stator 9 and the rotor 10 is provided inside the motor housing 8. The stator 9 is electrically connected to the controller 2, and the rotor 10 is drivingly connected to the fuel pump. The motor bracket 7 is snap-fitted below the mounting bracket 5. A flow cavity 14 is provided between the motor bracket 7 and the mounting bracket 5. One or more flow ports 21 communicating the flow cavity 14 with the motor cavity 81 are provided on the motor bracket 7.

[0028] The rotor 10 includes a rotating shaft 101, an iron core 102, and a rotating magnet 103. The rotating magnet 103 is injection-molded on the rotating shaft 101 using plastic magnetic material. A polygonal snap groove 20 is provided at one end of the rotating magnet 103. The fuel pump includes a filter screen assembly 13, a coupling 12 and a pump assembly 11 that are drivingly connected to each other. The filter screen assembly 13 is used to filter fuel. The coupling 12 is drivingly connected to the polygonal snap groove 20. As Figure 4 shown, the iron core 102 is fixedly sleeved on the rotating shaft 101, and the polygonal snap groove 20 is a hexagonal structure. According to the characteristics that various structures can be formed by plastic magnetic injection molding, an inner concave hexagonal structure matching the coupling 12 for transmitting torque is made at one end of the rotor 10 magnet. In this way, the rotor 10 magnet not only rotates, but also has the function of transmitting torque through the inner concave hexagonal structure, making the structure of the brushless pump simpler and more compact.

[0029] The outer surface of the oil outlet cover 1 is provided with a circumferentially extending annular groove 22. The lower part of the annular groove 22 is provided with an annular inclined surface 23. The upper part of the motor housing 8 covers the lower part of the oil outlet cover 1, the mounting bracket 5, and the motor bracket 7. The upper end of the motor housing 8 is provided with an annular edge 82 that is obliquely and inwardly bent. The annular edge 82 and the annular groove 22 form a snap fit. The upper part of the motor housing 8 can effectively prevent the mounting bracket 5 and the motor bracket 7 from being exposed outside, and prevent external contamination from contacting the controller 2 through the gap between the mounting bracket 5 and the motor bracket 7.

[0030] Operating principle: The positive and negative electrodes 18 are externally connected to direct current, which is converted into alternating current by the hall-free controller 2 and flows through the stator 9 to generate an alternating magnetic field, causing the rotor 10 to rotate. The pump assembly 11 is driven to rotate through the coupling 12, sucking the external oil fluid from outside the filter screen assembly 13, passing through the gap between the stator 9 and the rotor 10, flowing through the motor bracket 7, passing through the metal heat dissipation plate 6 and the mounting bracket 5, and finally discharging from the oil outlet nozzle 19 on the oil outlet cover 1.

[0031] Obviously, the above embodiments of the present invention are merely examples for illustrating the present invention, rather than limitations on the implementation manners of the present invention. For those of ordinary skill in the art, other different forms of changes or modifications can be made based on the above description. It is not necessary and impossible to list all implementation manners here. And these obvious changes or modifications derived from the essence of the present invention still fall within the protection scope of the present invention.

Claims

1. A brushless motor fuel pump with a built-in controller, comprising a control unit, a brushless motor, and a fuel pump connected in sequence. The control unit includes an oil outlet cover (1), a controller (2), a heat-conducting pad (3), a mounting bracket (5), and a metal heat sink (6). The mounting bracket (5) is fixedly installed at the upper end of the brushless motor. A circulation cavity (14) for oil to flow out is provided between the mounting bracket (5) and the upper end of the brushless motor. The circulation cavity (14), the brushless motor, and the fuel pump are connected in sequence. The oil outlet cover (1) is fixedly connected to the upper end of the mounting bracket (5), and the oil outlet cover (1) is provided with an oil outlet (15) communicating with the circulation cavity (14). The mounting bracket (5) and the oil outlet cover (1) are hermetically connected to form a sealed cavity (16) for installing the controller (2). The controller (2), the heat-conducting pad (3), and the metal heat sink (6) are connected in sequence from top to bottom. The lower part of the metal heat sink (6) is hermetically installed in a mounting hole provided in the mounting bracket (5). The metal heat sink (6) passes through the mounting hole and is exposed in the circulation cavity (14). The mounting bracket (5) and the oil outlet cover (1) are hermetically covered to form a box-shaped sealed structure. A sealing ring (4) is provided at the connection between the mounting bracket (5) and the oil outlet cover (1). The power components provided on the controller (2) are all arranged on the side close to the heat-conducting pad (3), and the power components are all in contact with the heat-conducting pad (3). The metal heat sink (6) includes a main board (61) connected to the heat-conducting pad (3) and a heat dissipation part (62) protruding downward relative to the main board (61). The heat dissipation part (62) forms a sealed connection with the mounting hole. The lower end of the heat dissipation part (62) is exposed in the circulation cavity (14), and a heat dissipation groove (63) corresponding to the circulation cavity (14) is provided in the heat dissipation part (62). The upper end of the oil outlet cover (1) is provided with an electrical connection slot (17) and an oil outlet nozzle (19). Electrodes (18) for electrically connecting the controller (2) are provided in the electrical connection slot (17). The oil outlet nozzle (19) communicates with the oil outlet (15). The oil outlet (15) is provided on one side of the oil outlet cover (1). The oil outlet (15) has a flat axial extension structure, and the oil outlet (15) covers one side of the sealed cavity (16).

2. The brushless motor fuel pump with a built-in controller according to claim 1, characterized in that: The brushless motor includes a motor housing (8), a stator (9), and a rotor (10). The motor housing (8) is fixedly connected to the control unit. A motor cavity (81) for accommodating the stator (9) and the rotor (10) is provided in the motor housing (8). The stator (9) is electrically connected to the controller (2), and the rotor (10) is drivingly connected to the fuel pump.

3. The brushless motor fuel pump with a built-in controller according to claim 2, characterized in that: The rotor (10) includes a rotating shaft (101) and a rotating magnet (103). The rotating magnet (103) is injection-molded on the rotating shaft (101) using plastic magnetic material. A polygonal clamping groove (20) is provided at one end of the rotating magnet (103). The fuel pump includes a coupling (12) and a pump assembly (11) that are drivingly connected to each other. The coupling (12) is drivingly connected to the polygonal clamping groove (20).

4. The brushless motor fuel pump with a built-in controller according to claim 3, characterized in that: The rotor (10) further includes an iron core (102), the iron core (102) is fixedly sleeved on a rotating shaft (101), and the polygonal clamping groove (20) is a hexagonal structure.

5. The brushless motor fuel pump with a built-in controller according to claim 3, characterized in that: The fuel pump further includes a filter screen assembly (13), and the filter screen assembly (13) is used for filtering fuel.

6. The brushless motor fuel pump with a built-in controller according to claim 2, characterized in that: The brushless motor further includes a motor bracket (7), the motor bracket (7) is clamped and installed below the mounting bracket (5), a circulation cavity (14) is provided between the motor bracket (7) and the mounting bracket (5), and the motor bracket (7) is provided with one or more circulation ports (21) communicating the circulation cavity (14) with the motor cavity (81).

7. The brushless motor fuel pump with a built-in controller according to claim 6, characterized in that: The outer surface of the oil outlet cover (1) is provided with a circumferentially extending annular groove (22), the lower part of the annular groove (22) is provided with an annular inclined surface (23), the upper part of the motor housing (8) covers the lower part of the oil outlet cover (1), the mounting bracket (5) and the motor bracket (7), and the upper end of the motor housing (8) is provided with an annular edge (82) bent obliquely inwards, and the annular edge (82) and the annular groove (22) form a clamping fit.

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