Pump set

Abstract

The invention relates to a pump pack (1) for a cooling system of an operating pack of a vehicle, which pump pack extends along an axis (X-X) and comprises: i) a pump body (2) comprising a first element (21), an intermediate element (22) and a second element (23), the coupling between the first element (21) and the intermediate element (22) defines a first chamber (200 '), and wherein the coupling between the intermediate element (22) and the second element (23) defines a second chamber (200' '); wherein the intermediate element (22) comprises a side wall (222) extending parallel to the axis (X-X) and comprises a bottom wall (223); ii) a stationary shaft (3) housed in said first chamber (200 '), said stationary shaft extending along said axis (X-X) between a first end (31) and a second end (32); iii) an electric motor (4) comprising a rotor (41) housed in the first chamber (200 ') and a stator (42) housed in the second chamber (200' '); iv) an impeller assembly (5) housed in the first chamber (200 '), comprising a blade element (50) and a rotating shaft (51) fitted to the stationary shaft (3) and engaged with the blade element (50) and the rotor (41). The bottom wall (223) comprises a metal plate (2230), preferably made of alloy steel, preferably stainless alloy steel, and the second end (32) of the stationary shaft (3) is integrally connected to the metal plate (2230).

Description

Technical Field

[0001] The present invention relates to a pump unit for a cooling system of a vehicle. Background Art

[0002] In the present disclosure, the term "vehicle" relates to any mobile device without any limitation on type or size, i.e., an automobile or a tractor-trailer.

[0003] In other words, the present invention relates to the field of automobiles and, in particular, to a thermal management system for an operating group of a vehicle.

[0004] Specifically, in the present disclosure, an "operating group" represents a specific component or a group of components for performing a given operation necessary for vehicle movement. In a preferred embodiment, the "operating group" includes, for example, a motor group of the heat-absorbing type, electric type, or hybrid type.

[0005] In a further structural variant, the "operating group" includes other vehicle components, including mechanical ones in the vehicle, such as a transmission group, or electrical ones, such as a "battery pack" or an "electric motor".

[0006] In the prior art, multiple embodiments of a pump unit for a cooling system of an operating group are known, which are distinguished by actuation type.

[0007] Specifically, the pump unit of the present invention is suitable for the case of the electro-actuation type. In other words, the pump unit of the present invention includes at least one electric motor that commands the rotational movement of an impeller assembly included therein, thereby commanding the movement of the cooling liquid flowing in the cooling system, to which the pump unit can be fluidly connected.

[0008] Multiple technical solutions of pump units including an electric drive device having an electric motor are known.

[0009] A typical problem solved in such products is to achieve effective cooling of electrical components, particularly with respect to an electronic command board.

[0010] In addition, embodiments of pump units are known from the prior art in which the rotor is "wet", i.e., it is in a water chamber, i.e., it is in the hydraulic part of the pump unit. However, in such an embodiment, the problem is the need for a complex positioning of the blade elements included in the impeller assembly and the rotor connected thereto, and an incorrect position thereof results in many inefficiency problems of the pump unit. Summary of the Invention

[0011] Therefore, an object of the present invention is to provide a pump unit for a cooling system of an operating group of a vehicle, which solves such typical problems of the prior art.

[0012] This object can be achieved by the pump unit according to claim 1. Its dependent claims relate to preferred structural variants having further advantageous aspects. Description of the Drawings

[0013] The object of the present invention will now be described in detail with the aid of the drawings, in which:

[0014] Figure 1 A side view of the pump unit according to the present invention is shown;

[0015] Figure 2 It is shown Figure 1 a perspective view of the separating part of the pump unit in;

[0016] Figure 3 It is shown along Figure 1 an axial sectional view of the pump unit taken along section A-A in;

[0017] Figure 3a It is shown Figure 3 an enlarged view of some details in. Detailed Description of the Invention

[0018] In the above-mentioned drawings, the reference numeral 1 as a whole denotes a pump unit for a cooling system of an operating group for a vehicle of, for example, the internal combustion type.

[0019] The pump unit 1 of the present invention mainly extends longitudinally along the axis X-X.

[0020] According to the present invention, the pump unit 1 includes a pump body 2 for supporting and containing the following components. Preferably, the pump body 2 can be fluidly connected to a pipe of the cooling system, and the cooling liquid moved by the pump unit 1 flows in this pipe.

[0021] According to a preferred embodiment, the "cooling liquid" is a water-based liquid, for example, a solution including water and ethylene glycol.

[0022] According to another preferred embodiment, the "cooling liquid" is an oil-based liquid.

[0023] The pump body 2 includes a first element 21, an intermediate element 22 and a second element 23. In other words, the pump body 2 includes three different elements, which, when assembled, define the pump body 2.

[0024] According to the present invention, the connection between the first element 21 and the intermediate element 22 defines a first chamber 200' or wet chamber.

[0025] According to the present invention, the connection between the intermediate element 22 and the second element 23 defines a second chamber 200'' or dry chamber. In fact, the two chambers are sealed from each other.

[0026] According to a preferred embodiment, the first element 21, the intermediate element 22 and the second element 23 are joined to each other along the axis X-X, with the intermediate element 22 being sandwiched between the first element 21 and the second element 23.

[0027] According to a preferred embodiment, the first element 21 and the second element 23 are joined to each other along the axis X-X, and the intermediate element 22 is received in the space defined thereby.

[0028] According to the present invention, the intermediate element 22 includes side walls 222 extending parallel to the axis X-X and includes a bottom wall 223.

[0029] According to a preferred embodiment, the bottom wall 223 includes a metal plate 2230.

[0030] Preferably, the metal plate 2230 is made of alloy steel, preferably made of stainless alloy steel.

[0031] According to a preferred embodiment, the side walls 222 are made of plastic material, and the metal plate 2230 is integrally connected to the side walls 222 by a co-molding operation of the bottom wall 223 and the side walls 222.

[0032] Preferably, the bottom wall 223, in particular the metal plate 2230, includes a radial edge 2230' adapted to engage the side walls 222.

[0033] Preferably, the radial edge 2230' is knurled to facilitate gripping of the side walls 222 during the co-molding operation.

[0034] Preferably, the radial edge 2230' includes steps adapted to promote a tight fixation between the side walls 222 and the bottom wall 223.

[0035] According to a preferred embodiment, except for the metal plate 2230, the pump body 2 is made of a material selected from the polymer family.

[0036] Preferably, the pump body 2 is made of PPS GF40, PA6.10 and PBT GF20.

[0037] According to a preferred embodiment, the pump unit 1 includes a fixed shaft 3 received in a first chamber 200'.

[0038] Preferably, the fixed shaft 3 is made of a material selected from alloy steel, preferably made of chrome alloy steel.

[0039] The fixed shaft 3 extends along the axis X-X between a first end 31 and a second end 32 that engages the bottom wall 223.

[0040] In other words, the fixed shaft 3 is cantilevered with respect to the bottom wall 223.

[0041] According to a preferred embodiment, the second end 32 is engaged with the bottom wall by geometric interference coupling.

[0042] According to the present invention, the second end 32 is integrally connected to the metal plate 2230.

[0043] According to a preferred embodiment, the metal plate 2230 includes an opening 2230", and the second end 32 is received in the opening 2230".

[0044] Preferably, the second end 32 is received in the opening 2230" by geometric interference, i.e., by interfering with the edge of the opening 2230".

[0045] According to a preferred embodiment, the fixed shaft 3 and the metal plate 2230 are a single metal component.

[0046] In addition, the pump unit 1 includes an electric motor 4, which includes a rotor 41 received in a first chamber 200', and a stator 42 axially and circumferentially surrounding the rotor 41 received in a second chamber 200".

[0047] Preferably, the electric motor 4 is of the brushless type.

[0048] Preferably, the rotor 41 is of the permanent magnet type.

[0049] According to a preferred embodiment, the pump unit 1 further includes an impeller assembly 5 received in the first chamber 200'.

[0050] According to one embodiment, the impeller assembly 5 is rotationally driven by the electric motor 4.

[0051] The impeller assembly 5 includes blade elements 50 and a rotating shaft 51 assembled to the fixed shaft 4, and the rotating shaft engages with the blade elements 50 and the rotor 41.

[0052] In other words, the blade elements 50 are engaged with the rotating shaft 51 such that rotation of the rotating shaft 51 causes rotation of the blade elements 50.

[0053] According to a preferred embodiment, the rotating shaft 51 includes a water channel extending along the axis X-X, and the cooling liquid passing through the water channel reaches the bottom wall 223.

[0054] Preferably, the water channel is located on the outer surface of the rotating shaft 51, i.e., facing the rotor 41.

[0055] Preferably, the water channel is located on the inner surface of the rotating shaft 51, i.e., facing the fixed shaft 3.

[0056] Preferably, the water channel is inside the rotating shaft 51.

[0057] According to the present invention, the pump assembly 1 further includes a fixed bushing 6 which is integrally joined to the first end 31 to provide an axial stop for the impeller assembly 5.

[0058] In other words, the fixed bushing 6 is positioned to provide an upper axial stop for the axial movement of the impeller assembly 5. In fact, the impeller assembly 5 undergoes axial movement along the fixed shaft 3 under the action of the cooling liquid. In other words, the presence of the fixed bushing 6 on the fixed shaft 3 thus imposes an upper limiting stop for the said axial movement. In yet other words, the presence of the fixed bushing 6 defines the maximum axial position of the impeller assembly 5 in the first chamber 200'.

[0059] Preferably, the fixed bushing 6 is cylindrical, conical or flanged in shape.

[0060] Preferably, the fixed bushing 6 is fixed to the fixed shaft 3 and engages therewith with a geometric interference.

[0061] According to a preferred embodiment, the intermediate element 22 includes a top wall 221 axially remote from the bottom wall 223, wherein the vane element 50 is positioned between the said top wall 221 and the first element 21.

[0062] Preferably, the presence of the fixed bushing 6 on the fixed shaft 3 defines the maximum axial position of the vane element 50 in the space between the said top wall 221 and the first element 21.

[0063] According to a preferred embodiment, the first element 21 includes an inlet opening 211 on the axis X-X and a radial outlet 212, wherein the first element 21 is shaped to include a volute 210. In a preferred embodiment, the first element 21 includes an inlet duct extending along the axis X-X between the inlet opening 211 and a duct opening directly facing the first chamber 200'. In a preferred embodiment, the first end 31 of the fixed shaft 3 is at least partially received in the inlet duct and / or the duct opening. In a preferred embodiment, the fixed bushing 6 joined to the first end 31 of the fixed shaft 3 is at least partially received in the inlet duct and / or the duct opening. In a preferred embodiment, the first end 31 of the fixed shaft 3 is cantilevered from the bottom wall 223 of the intermediate element 22. Preferably, along the axis X-X, the impeller assembly 5 is proximal to the first end 31 of the fixed shaft 3. In a preferred embodiment, along the axis X-X, the impeller assembly 5 is proximal to the fixed bushing 6. In a preferred embodiment, along the axis X-X, the backing element 562 is engaged between the fixed bushing 6 and the impeller assembly 5, for example axially adjacent. Preferably, the said backing element 562 has a reduced dimension along the axis X-X such that the impeller assembly 5 is proximal to the first cantilever end 31. The above features are in Figure 3 and Figure 3aIt is shown by way of examples.

[0064] According to a preferred embodiment, the pump unit 1 further comprises a command unit 9 adapted to command the operation of the stator 42 and thus the rotation of the rotor 41, wherein the command unit 9 is housed in a second chamber 200”.

[0065] The command unit 9 is preferably operatively connected to the metal plate 2230 by a thermally conductive connecting element 95. Preferably, the thermally conductive connecting element 95 is an electrical insulator. For example, the thermally conductive connecting element 95 is a silicone sheet containing ceramic particles.

[0066] Preferably, the command unit 9 is a circuit board operatively connected to the stator 42, for example by a suitable connection.

[0067] Innovatively, the pump unit greatly achieves its intended purpose by overcoming typical problems of the prior art.

[0068] Advantageously, in fact, the pump unit has an impeller assembly and a rotor housed in the same chamber, both being wetted by the cooling liquid.

[0069] Advantageously, the pump unit solves the problem of positioning the blade elements relative to the axis of rotation.

[0070] Advantageously, the pump unit solves the problem of positioning the rotor relative to the axis of rotation. Advantageously, the air gap between the rotor and the stator is minimized, thereby improving the efficiency of the electric motor.

[0071] Advantageously, the first chamber and the second chamber are closely separated.

[0072] Advantageously, the metal plate can be tightly fixed to the side wall during manufacturing by a co - molding operation.

[0073] Advantageously, the metal plate promotes heat exchange between the first chamber and the second chamber.

[0074] Advantageously, the metal plate allows the heat generated by the command unit to be dissipated by the cooling liquid.

[0075] Advantageously, the cooling liquid reaches the metal plate through the water channels on the rotating shaft and wets and cools it. Thus, the metal plate is a multi - functional component, which can be sized as needed to balance the total weight of the pump unit, acting as a counterweight to ensure the correct cantilever configuration of the fixed shaft. This problem is particularly evident in the automotive field, where weight balance and weight reduction result in lower fuel consumption and volume optimization. Additionally, the metal plate serves as a heat catalyst and a heat conduction element towards the chamber wetted by the cooling liquid, for example and in particular for embodiments of pump bodies made of polymer materials. This problem is particularly evident in the automotive field, where the space around the pump unit and the temperature of the components impede effective thermal management.

[0076] Advantageously, the positioning of the fixed axis is determined over time.

[0077] Advantageously, the blade elements can be positioned to have a defined and distinct minimum axial position and maximum axial position over time.

[0078] Advantageously, the pump set is quiet, solving the noise problem caused by incorrect positioning of the blade elements.

[0079] Advantageously, the pump set has a simple construction.

[0080] Obviously, those skilled in the art can make changes to the above invention to meet possible requirements, and all such changes are included within the scope of protection defined by the appended claims.

Claims

1. A pump unit (1) for a cooling system of an operating group for a vehicle, the pump unit extending along an axis (X-X) and comprising: i) A pump body (2) including a first element (21), an intermediate element (22) and a second element (23), wherein the connection between the first element (21) and the intermediate element (22) defines a first chamber (200') or wet chamber, and wherein the connection between the intermediate element (22) and the second element (23) defines a second chamber (200") or dry chamber, and wherein the intermediate element (22) includes a side wall (222) extending parallel to the axis (X-X) and includes a bottom wall (223); ii) A fixed shaft (3) received in the first chamber (200'), the fixed shaft extending along the axis (X-X) between a first end (31) and a second end (32); iii) An electric motor (4) including a rotor (41) received in the first chamber (200') and a stator (42) received in the second chamber (200"), the stator axially and circumferentially surrounding the rotor (41); iv) An impeller assembly (5) received in the first chamber (200'), the impeller assembly including blade elements (50) and a rotating shaft (51), the rotating shaft being assembled to the fixed shaft (3) and engaging with the blade elements (50) and the rotor (41); wherein the bottom wall (223) includes a metal plate (2230), preferably the metal plate is made of alloy steel, preferably made of stainless alloy steel, and the second end (32) of the fixed shaft (3) is firmly connected to the metal plate (2230).

2. The pump unit according to claim 1, wherein, The metal plate (2230) includes an opening (2230"), and the second end (32) is received in the opening (2230").

3. The pump unit according to claim 2, wherein, The second end (32) is received in the opening (2230") by geometric interference.

4. The pump unit according to claim 1, wherein, The fixed shaft (3) and the metal plate (2230) are a single metal part.

5. The pump unit according to any one of the preceding claims, wherein, The side wall (22) is made of plastic material, and the metal plate (2230) is integrally connected to the side wall (22) by a co-molding operation of the bottom wall (23) and the side wall (22).

6. The pump unit according to any one of the preceding claims, wherein, It further includes a fixed bushing (6), preferably the fixed bushing is shaped as cylindrical, conical or flanged, and the fixed bushing is firmly connected to the first end (31) to provide an axial stop to the impeller assembly (5).

7. The pump unit according to any one of the preceding claims, wherein, The fixed shaft (3) is made of a material selected from alloy steel, preferably the fixed shaft is made of chrome alloy steel.

8. The pump unit according to any one of the preceding claims, wherein, The intermediate element (22) includes a top wall (221) axially away from the bottom wall (223), and the blade elements (50) are positioned between the top wall (221) and the first element (21).

9. The pump unit according to any one of the preceding claims, wherein, The first element (21) includes an inlet opening (211) on the axis (X-X) and includes a radial outlet (212), and the first element (21) is shaped to include a volute (210).

10. The pump unit according to any one of the preceding claims, wherein, The first element (21), the intermediate element (22) and the second element (23) are joined to each other along the axis (X-X), wherein the intermediate element (22) is sandwiched between the first element (21) and the second element (23).

11. The pump unit according to any one of the preceding claims, wherein, The rotating shaft (51) includes a water channel extending along the axis (X-X), wherein cooling liquid passes through the water channel to reach the bottom wall (223).

12. The pump unit according to any one of the preceding claims, wherein, It further includes a command unit (9) adapted to command the operation of the stator (42) and thus command the rotation of the rotor (41), wherein the command unit (9) is housed in the second chamber (200”), wherein the command unit (9) is operatively connected to the metal plate (2230), preferably, the command unit is operatively connected to the metal plate through a heat-conducting connecting element (95), for example, the heat-conducting connecting element is a silicone sheet containing ceramic particles.

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