Highly integrated electric pump

Abstract

The invention discloses a highly integrated electric pump, relates to the technical field of fluid machinery, solves the technical problems of high energy consumption, large size, heavy weight, easy leakage and inconvenience in maintenance of a traditional water pump, and comprises a shell, a shell cover, a rim type motor and an impeller, two power installation cavities and a central impeller installation cavity which are symmetrically distributed are formed in the shell in an integrated casting mode, the two rim type motors are installed in the power installation cavities in an interference pressing mode, and conical positioning bosses are arranged at the ends of hollow shafts of the rim type motors and connected with two end opening rings of an impeller through keys. A first suction pipe and a second suction pipe obliquely extend from two sides of the shell, and an output pipe is arranged on the center line of the top. Through precision casting and thermal management optimization, the structure compactness and the operation stability are achieved, and the high-precision fluid conveying device is suitable for a high-precision fluid conveying system and has the functions of vibration suppression, quick response and fault self-protection.

Description

Technical Field

[0001] The present invention relates to the technical field of fluid machinery, and more specifically, to a highly integrated electric pump. Background Art

[0002] The matching between traditional water pump motors and pump bodies is poor, and they lack intelligent speed regulation functions, resulting in significant energy consumption waste during low-flow or variable operating conditions. Traditional water pumps need to adopt a symmetric double-suction impeller design to balance axial forces, which leads to a large and heavy pump body, increasing the installation and handling costs, and is especially not suitable for scenarios with limited space (such as construction sites, small equipment). Traditional water pumps mostly use packing seals or ordinary mechanical seals, and leakage is likely to occur due to wear or corrosion during long-term operation, and the seals need to be frequently replaced. The key components such as bearings and shaft seals of traditional water pumps are integrated inside the pump body, and disassembly and repair require overall disassembly, which is time-consuming and laborious. Summary of the Invention

[0003] The purpose of the present invention is to provide a highly integrated electric pump to solve the technical problems of high energy consumption, large size, heavy weight, easy leakage, and inconvenient maintenance of traditional water pumps.

[0004] The technical solution adopted by the present invention is as follows: A highly integrated electric pump includes a housing, a shell cover, a rim-type motor, and an impeller;

[0005] The housing is integrally cast to form two symmetrically distributed power installation cavities and a central impeller installation cavity;

[0006] Two rim-type motors are press-fitted into the power installation cavities with interference. The end of the hollow shaft of the rim-type motor is provided with a tapered positioning boss, and the two port rings at both ends of the impeller are connected by keys;

[0007] The first suction pipe and the second suction pipe extend obliquely from both sides of the housing, and the axis of the pipe forms an angle of 15° - 25° with the horizontal plane.

[0008] Among them, an output pipe with a Venturi acceleration section is provided at the top midline, and the ratio of the throat diameter of the output pipe to the outlet diameter of the impeller is 1:1.2 - 1.5;

[0009] The shell cover is bonded to the housing with a high-temperature sealant containing ceramic fiber, and three staggered labyrinth seal teeth are provided on the joint surface.

[0010] The integrally cast three-cavity structure ensures high coaxiality (≤0.05 mm), reduces assembly errors, and improves operation stability; the interference press-fitting of the rim-type motor and the laser welding of the impeller enhance the structural rigidity, reduce vibration and energy loss; the oblique design of the suction pipe optimizes the fluid inlet flow pattern, and the acceleration section of the Venturi output pipe improves the output efficiency (throat diameter ratio 1:1.2 - 1.5); the staggered labyrinth seal teeth combined with the high-temperature sealant significantly improve the sealing reliability and are suitable for high-pressure and high-temperature working conditions.

[0011] Preferably, the shell cover is locked by a star - arranged pre - tension adjustable bolt group. The bolt group includes a plurality of alloy bolts evenly distributed along the circumference, and the pre - tightening torque is 25 - 35 N·m. The star - arranged titanium alloy bolt group provides uniform pre - tightening force (25 - 35 N·m) to avoid deformation of the shell cover and sealing failure; the lightweight titanium alloy bolts are corrosion - resistant and suitable for marine or chemical environments; the circumferential uniform distribution design enhances the structural symmetry and suppresses vibration transmission.

[0012] Preferably, for the rim - type motor, the stator core and the inner wall of the outer shell adopt a water - cooling structure or a double - stator disc structure. A thermal conductive silicone grease layer containing 25 - 30 wt% boron nitride is filled between the stator core and the inner wall of the outer shell, and a 0.3 - mm - thick Al2O3 - ZrO2 composite ceramic coating is provided on the outer surface of the outer shell. The double - stator disc motor improves the power density and optimizes the space utilization rate; the high - thermal - conductivity silicone grease (containing 25 - 30 wt% boron nitride) accelerates the heat dissipation of the stator, reducing the temperature rise by 10% - 15%; the Al2O3 - ZrO2 composite ceramic coating enhances the wear resistance and heat insulation performance of the outer shell and extends the service life.

[0013] Preferably, the flanges of the first suction pipe and the second suction pipe are integrally cast and merged into one suction pipe. The flange end faces of the first suction pipe and the second suction pipe are processed with 6 - 8 radial flow - guiding grooves with a depth of 0.5 mm, and the groove width gradually expands from 2 mm to 5 mm from the inside to the outside. The radial flow - guiding grooves (depth 0.5 mm, gradually expanding groove width) guide the uniform distribution of the fluid, reducing the risk of inlet eddy current and cavitation; the gradually expanding groove design matches the velocity gradient, reducing the local resistance loss and increasing the suction efficiency by about 8% - 12%.

[0014] Preferably, the impeller adopts forward - swept three - dimensional twisted blades. The leading edge of the blade is of NACA64 airfoil type, the taper of the conical interface of the hub is 1:10, and the surface hardness is ≥800 HV. The combination of forward - swept three - dimensional twisted blades and NACA64 airfoil type improves the head and efficiency and reduces the cavitation tendency; the conical interface (1:10 taper) ensures the precise positioning of the impeller and the hollow shaft, and the surface hardness ≥800 HV enhances the abrasion - resistance ability.

[0015] Preferably, a spiral cooling flow channel is provided at the bottom of the power installation cavity. The cross - sectional area of the flow channel decreases by 6% from the inlet to the outlet, and turbulence - enhancing ribs with a height of 0.1 mm are provided on the inner wall of the flow channel. The 6% decrease in the cross - sectional area of the spiral cooling flow channel maintains the flow velocity of the cooling medium and enhances the uniformity of heat dissipation; the turbulence - enhancing ribs (0.1 mm high) break the laminar boundary layer, increasing the heat transfer coefficient by 20% - 30% and preventing local overheating.

[0016] Preferably, it further includes an annular damping assembly inside the housing cover, which includes 8 rubber-metal laminated dampers with circumferentially gradient distribution. The stiffness coefficient increases from 50 N / mm at the 0° position to 85 N / mm at the 180° position. The circumferentially gradient distribution of the rubber-metal laminated dampers (with a stiffness of 50 - 85 N / mm) specifically suppresses broadband vibration; multiple dampers cooperate to dissipate energy, reducing the resonance amplitude by more than 40% and extending the service life of bearings and seals.

[0017] Preferably, a non-contact torque sensor is embedded in the hollow shaft of the rim-type motor. The gap between the sensor probe and the shaft is 0.3 - 0.5 mm, and the sampling frequency is ≥1 kHz. The non-contact torque sensor (with a gap of 0.3 - 0.5 mm) enables wear-free real-time monitoring, and a sampling frequency of ≥1 kHz ensures the dynamic response accuracy; the data feedback is used for motor load optimization, preventing overload faults and improving the energy efficiency ratio.

[0018] Preferably, an intelligent control box is integrated on the top of the housing, which includes: a dual-motor vector control module to achieve differential frequency control of 0.1 - 5 Hz; a pressure feedback adjustment unit with a response time ≤10 ms; a CAN bus interface that supports networking of ≥32 devices. The differential frequency control of the dual motors (0.1 - 5 Hz) realizes stepless adjustment of flow rate / pressure, adapting to complex working conditions; the pressure feedback response ≤10 ms, and the dynamic stability is superior to traditional PID control; the CAN bus supports networking of multiple devices (≥32), facilitating industrial Internet of Things integration.

[0019] Preferably, a fault diagnosis algorithm is built into the control box, which can identify more than 5 abnormal vibration spectra and trigger a load reduction protection of 30% - 70% of the corresponding motor power. The fault diagnosis algorithm identifies more than 5 abnormalities (such as imbalance, bearing wear) through vibration spectra, achieving precise early warning; triggering the load reduction protection (30% - 70% of the power) avoids sudden shutdowns, ensures the safe operation of the system, and reduces maintenance costs.

[0020] In summary, due to the adoption of the above technical solutions, the beneficial effects of the present invention are:

[0021] The structural precision and operation stability of the present invention are significantly improved. The coaxiality tolerance of ≤0.05 mm is achieved on the surface in the three-chamber structure (two power installation chambers + a central impeller chamber) of integral casting, fundamentally ensuring the dynamic balance of the dual-motor drive system and reducing vibration and noise; the rim-type motor is press-fitted with interference on the hollow shaft's conical positioning boss to form a high-precision mechanical coupling, and the laser welding process is used to increase the impeller connection strength by more than 40%; the combination of three staggered labyrinth seal teeth and ceramic fiber sealant maintains the IP68 protection level even under the working condition of 350°C.

[0022] The hydrodynamic efficiency of the present invention is optimized. The double-suction pipe with an inclination angle of 15°-25° combined with the design of radial guide grooves reduces the pre-whirl loss of the fluid by 18%. The venturi acceleration section is designed with a contraction ratio of the throat diameter of 1:1.2-1.5, increasing the outlet flow velocity to 1.3 times that of the conventional design. The combination of forward-swept three-dimensional twisted blades and NACA64 airfoils achieves a hydraulic efficiency of 92% at a rotational speed of 2000 r / min, which is 5-7 percentage points higher than that of traditional impellers.

[0023] The thermal management and durability of the present invention are improved. The synergistic effect of boron nitride thermal conductive silicone grease (thermal conductivity > 3.5 W / m·K) and spiral cooling channels controls the motor temperature rise within 45 K. The Al2O3-ZrO2 composite ceramic coating extends the erosion-resistant life of the shell to 12000 hours. The titanium alloy bolt group realizes thermal deformation compensation through the pre-tightening force gradient distribution (25-35 N·m) to ensure the stability of the sealing surface under high-temperature conditions.

[0024] The intelligent control and operation and maintenance of the present invention are innovated. The differential frequency control of the dual motors (0.1-5 Hz) enables the flow regulation accuracy to reach ±1.5%. The non-contact torque sensor (sampling at 1 kHz) monitors the load fluctuation in real time. Combining with the fault diagnosis algorithm, it can identify abnormal vibrations within 5 ms and start hierarchical load reduction protection to avoid more than 80% of sudden failures. The CAN bus networking ability supports the collaborative control of large-scale systems, reducing the operation and maintenance labor cost by 30%.

[0025] The environmental adaptability of the present invention is enhanced. The stiffness gradient design of the rubber-metal laminated damper effectively absorbs broadband vibrations from 6-500 Hz, enabling the equipment to still operate stably in seismic environment class IV. The impeller with a surface hardness ≥ 800 HV can withstand the wear of media with a solid content of 15%, expanding the application range in harsh working conditions such as mines and chemical industries.

[0026] In summary, through the deep integration of structural innovation, material optimization and intelligent control, the present invention has achieved a leapfrog upgrade in the energy efficiency index (the comprehensive energy efficiency reaches IE5 level), reliability (MTBF > 50000 hours) and intelligent level of the electric pump products, with significant market competitive advantages. Brief Description of the Drawings

[0027] The present invention will be described by way of examples and with reference to the accompanying drawings, wherein:

[0028] Figure 1 is an isometric view of the present invention;

[0029] Figure 2 is another isometric view of the present invention;

[0030] Figure 3 is a front view structural schematic diagram of the present invention;

[0031] Figure 4 It is a schematic cross-sectional view of the A-A section of the present invention;

[0032] Figure 5 It is a schematic side view of the present invention;

[0033] Figure 6 It is a schematic cross-sectional view of the B-B section of the present invention;

[0034] In the figure, the markings are: 1 - outer shell, 2 - shell cover, 3 - rim-type motor, 4 - impeller, 11 - power installation cavity, 12 - impeller installation cavity, 13 - first suction pipe, 14 - second suction pipe, 15 - output pipe. Specific embodiments

[0035] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are some, but not all, of the embodiments of the present invention. Usually, the components of the embodiments of the present invention described and shown in the accompanying drawings here can be arranged and designed in various different configurations.

[0036] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed present invention, but merely represents the selected embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts fall within the scope of protection of the present invention.

[0037] In one embodiment of the present invention, as Figure 1-6 shown, this embodiment provides a highly integrated electric pump, including an outer shell 1, a shell cover 2, a rim-type motor 3, and an impeller 4;

[0038] The outer shell 1 is integrally cast to form two symmetrically distributed power installation cavities 11 and a central impeller installation cavity 12, and the coaxiality tolerance of the three cavities is ≤0.05 mm;

[0039] Two rim-type motors 3 are press-fitted into the power installation cavities 11 with interference. The end of the hollow shaft of the rim-type motor 3 is provided with a conical positioning boss, and the two port rings at both ends of the impeller 4 are connected by laser welding;

[0040] On both sides of the outer shell 1, the first suction pipe 13 and the second suction pipe 14 extend obliquely. The axis of the pipe forms an angle of 15° - 25° with the horizontal plane. The output pipe 15 with a Venturi acceleration section is provided at the midline of the top. The ratio of the throat diameter of the output pipe 15 to the outlet diameter of the impeller 4 is 1:1.2 - 1.5;

[0041] The shell cover 2 is bonded to the outer shell 1 with a high-temperature sealant containing ceramic fiber, and three staggered labyrinth seal teeth are provided on the joint surface.

[0042] Among them, the integrated casting three-cavity structure ensures high coaxiality (≤0.05 mm), reduces assembly errors, and improves operation stability; the interference fit and laser welding of the impeller 4 of the rim-type motor 3 enhance the structural rigidity, reduce vibration and energy loss; the inclined design of the first suction pipe 13 and the second suction pipe 14 optimizes the fluid inlet flow pattern, and the acceleration section of the Venturi output pipe 15 improves the output efficiency (the throat diameter ratio is 1:1.2 - 1.5); the staggered labyrinth seal teeth combined with high-temperature sealant significantly improve the sealing reliability and are suitable for high-pressure and high-temperature working conditions.

[0043] Specifically, the housing 1 is integrally formed by low-pressure casting using ZL205A high-strength aluminum alloy. When casting, a three-coordinate linkage metal mold is used to ensure that the coaxiality of the two power installation cavities 11 and the impeller installation cavity 12 is ≤0.05 mm. The hollow shaft of the rim-type motor 3 is made of 42CrMo steel, and a positioning boss with a taper angle of 60° is machined at its end, and is connected to the 304 stainless steel mouth ring of the impeller 4 by laser welding (welding power 3.5 kW, scanning speed 12 mm / s). The first suction pipe 13 and the first suction pipe 13 adopt a 22.5° inclined design, and the output pipe 15 is embedded with a Venturi section, and the throat diameter of 32 mm corresponds to the impeller 4 outlet diameter of 40 mm (ratio 1:1.25). The shell cover 2 is bonded with HT-800 high-temperature sealant containing 30% ceramic fiber, and three staggered labyrinth seal teeth with a machining depth of 0.8 mm and a tooth width of 1.2 mm are processed on the joint surface.

[0044] In another embodiment of the present invention, the shell cover 2 is locked by a star-shaped arrangement of pre-tightening force adjustable bolt groups. The bolt group includes a plurality of alloy bolts evenly distributed along the circumference, and the pre-tightening torque is 25 - 35 N·m. The star-shaped arrangement of titanium alloy bolt groups provides uniform pre-tightening force (25 - 35 N·m) to avoid deformation and sealing failure of the shell cover 2; the lightweight titanium alloy bolts are corrosion-resistant and are suitable for marine or chemical environments; the circumferential uniform distribution design enhances the structural symmetry and suppresses vibration transmission.

[0045] Specifically, 8 evenly distributed M10 threaded holes are machined on the mounting surface of the shell cover 2, and TC4 titanium alloy bolts (tensile strength ≥900 MPa) are tightened in three times in a star-shaped order: first pre-tightened to 15 N·m, second cross-tightened to 25 N·m, and finally calibrated to 30 ± 2 N·m using a torque wrench. A wave spring washer is installed on the bolt head to maintain a pre-tightening force attenuation rate of <5% under the working condition of 150°C.

[0046] In another embodiment of the present invention, for the rim-type motor 3, the stator core and the inner wall of the housing adopt a water-cooling structure or a double-stator disc structure. A heat-conducting silicone grease layer containing 25-30 wt% boron nitride is filled between the stator core and the inner wall of the housing 1. An Al2O3-ZrO2 composite ceramic coating with a thickness of 0.3 mm is provided on the outer surface of the housing 1. The double-stator disc motor improves the power density and optimizes the space utilization rate; the high heat-conducting silicone grease (containing 25-30 wt% boron nitride) accelerates the heat dissipation of the stator and reduces the temperature rise by 10%-15%; the Al2O3-ZrO2 composite ceramic coating enhances the wear resistance and heat insulation performance of the housing 1 and prolongs the service life.

[0047] Specifically, the rim-type motor 3 adopts a double-stator disc structure. The distance between the two stator cores is 8 mm, and a neodymium-iron-boron permanent magnet is embedded in the middle. The heat-conducting silicone grease is of the Dow Corning TC-5625 type and is mixed with 27% boron nitride powder (particle size 5-10 μm) by mass ratio. The composite ceramic coating adopts a plasma spraying process. First, an Al2O3 bottom layer with a thickness of 0.2 mm is sprayed, and then a ZrO2 surface layer with a thickness of 0.1 mm is sprayed. After heat treatment at 800 °C, a dense structure is formed.

[0048] In another embodiment of the present invention, the flanges of the first suction pipe 13 and the second suction pipe 14 are merged and integrally cast into one, forming a combined suction pipe. The flange end faces of the first suction pipe 13 and the second suction pipe 14 are machined with 6-8 radial flow guiding grooves with a depth of 0.5 mm, and the groove width gradually expands from 2 mm to 5 mm from the inside to the outside. The radial flow guiding grooves (depth 0.5 mm, gradually expanding groove width) guide the uniform distribution of the fluid, reducing the risk of inlet eddy current and cavitation; the gradually expanding groove design matches the velocity gradient, reducing the local resistance loss and increasing the suction efficiency by about 8%-12%.

[0049] Specifically, 7 radial flow guiding grooves are machined on the flange end faces of the first suction pipe 13 and the second suction pipe 14 by a numerical control machine tool. The groove depth is 0.5 mm ± 0.05, the starting width at the inner end is 2 mm, and it gradually increases to 5 mm at the outer end at a gradient of 0.3 mm per millimeter of outward expansion. The bottom of the groove is designed with a 0.2 mm fillet, and the surface is subjected to electrolytic polishing treatment (Ra ≤ 0.8 μm). It is verified by CFD simulation that the inlet eddy current intensity can be reduced by 42%.

[0050] In another embodiment of the present invention, the impeller 4 adopts forward-swept three-dimensional twisted blades. The leading edge of the blade is of the NACA64 airfoil type. The taper of the conical interface of the hub is 1:10, and the surface hardness is ≥ 800 HV. The combination of the forward-swept three-dimensional twisted blades and the NACA64 airfoil type improves the head and efficiency and reduces the cavitation tendency; the conical interface (1:10 taper) ensures the precise positioning of the impeller 4 and the hollow shaft, and the surface hardness ≥ 800 HV enhances the abrasion resistance.

[0051] Specifically, the impeller 4 is manufactured by a 5-axis linkage machining center. The leading edge of the blade is formed according to the NACA64-415 airfoil, and the maximum thickness position is at 30% of the chord length. The conical interface of the hub is nitrided (ammonia decomposition rate 35%, holding at 520 °C for 8 hours), the surface hardness reaches 820 HV, and the conical surface fitting clearance is 0.01 - 0.03 mm. The dynamic balance grade reaches G2.5, and the residual unbalance amount < 0.5 g·mm / kg.

[0052] In another embodiment of the present invention, a spiral cooling channel is provided at the bottom of the power installation cavity 11. The cross-sectional area of the channel decreases by 6% from the inlet to the outlet, and turbulence intensifying ribs with a height of 0.1 mm are provided on the inner wall of the channel. The 6% decrease in the cross-sectional area of the spiral cooling channel maintains the flow rate of the cooling medium and enhances the uniformity of heat dissipation; the turbulence intensifying ribs (0.1 mm high) break the laminar boundary layer and increase the heat transfer coefficient by 20% - 30%, preventing local overheating.

[0053] Specifically, the cross-section of the spiral cooling channel is a 4 mm × 6 mm rectangle, and a variable cross-section design is adopted. The perimeter of each turn of the spiral decreases by 2.4 mm, and the total length of the flow channel is 3.2 m. The turbulence intensifying ribs are arranged in a 45° helical tooth pattern, with a tooth pitch of 8 mm. Through tests, the heat transfer coefficient of the coolant can be increased by 18%. The pressure difference between the inlet and outlet of the channel is controlled within 0.15 - 0.2 MPa, and an external plate heat exchanger (heat transfer capacity ≥ 5 kW) is provided.

[0054] In another embodiment of the present invention, it further includes an annular damping assembly inside the housing cover 2, which includes 8 groups of rubber-metal laminated dampers with circumferential gradient distribution. The stiffness coefficient increases from 50 N / mm at the 0° position to 85 N / mm at the 180° position. The circumferential gradient distribution of the rubber-metal laminated dampers (stiffness of 50 - 85 N / mm) specifically suppresses broadband vibration; multiple groups of dampers cooperate to dissipate energy, reducing the resonance amplitude by more than 40% and extending the service life of bearings and seals.

[0055] Specifically, the annular damping assembly includes 8 groups of dampers arranged in an L shape. Each group is alternately laminated by 3 pieces of 304 stainless steel sheets with a thickness of 0.5 mm and 2 layers of fluororubber with a hardness of 50 shore A. A unit with a stiffness of 50 N / mm is installed at the 0° position, and the stiffness increases by 5 N / mm every 45°, and the unit with the maximum stiffness is located in the 180° direction. The pre-compression amount of the damper is set to 0.8 mm, which can attenuate vibrations below 200 Hz by more than 12 dB.

[0056] In another embodiment of the present invention, a non-contact torque sensor is embedded in the hollow shaft of the rim-type motor 3. The gap between the sensor probe and the shaft is 0.3 - 0.5 mm, and the sampling frequency ≥ 1 kHz. The non-contact torque sensor (gap of 0.3 - 0.5 mm) realizes wear-free real-time monitoring, and the sampling frequency ≥ 1 kHz ensures the dynamic response accuracy; the data feedback is used for motor load optimization, preventing overload faults and improving the energy efficiency ratio.

[0057] Specifically, the non-contact torque sensor uses TMR magnetoresistive elements, and a FeCo magnetostrictive layer is laser-clad on the inner wall of the hollow shaft. The installation gap of the probe is 0.4mm ± 0.05. The sampling circuit is designed with a band-pass filter (50 - 2000Hz), the sampling rate of each channel is 1.2kHz, and data is transmitted through Bluetooth 5.0 (transmission delay < 5ms). The non-linearity error of the calibration curve is ≤ 0.5% FS.

[0058] In another embodiment of the present invention, an intelligent control box is integrated on the top of the housing 1, which includes: a dual-motor vector control module to achieve differential frequency control of 0.1 - 5Hz; a pressure feedback regulation unit with a response time ≤ 10ms; and a CAN bus interface that supports networking of ≥ 32 devices. The dual-motor differential frequency control (0.1 - 5Hz) realizes stepless adjustment of flow rate / pressure, adapting to complex working conditions; the pressure feedback response ≤ 10ms, and the dynamic stability is better than that of traditional PID control; the CAN bus supports multi-device networking (≥ 32 devices), facilitating industrial Internet of Things integration.

[0059] Specifically, the intelligent control box is built with an STM32H743 dual-core processor. The vector control module uses the space vector pulse width modulation (SVPWM) algorithm, and the differential frequency control accuracy is ± 0.05Hz. The pressure sensor MPX5700AP is selected, the feedback signal is converted by a 24-bit ADC, and the control period is 1ms. The CAN bus interface complies with the ISO11898-2 standard, and the baud rate is set to 500kbps when supporting 32-node networking.

[0060] In another embodiment of the present invention, the control box is built with a fault diagnosis algorithm that can identify more than 5 abnormal vibration spectra and trigger a load reduction protection corresponding to 30% - 70% of the motor power. The fault diagnosis algorithm identifies more than 5 abnormalities (such as imbalance, bearing wear) through vibration spectra, achieving precise early warning; triggering load reduction protection (power 30% - 70%) avoids sudden shutdowns, ensures the safe operation of the system, and reduces maintenance costs.

[0061] Specifically, the fault diagnosis algorithm establishes a database containing 6 types of typical faults:

[0062] ① Blade fracture (characteristic frequency 82Hz ± 3)

[0063] ② Bearing wear (125Hz sideband)

[0064] ③ Cavitation (high-frequency noise > 2kHz)

[0065] ④ Misalignment (2x frequency vibration)

[0066] ⑤ Winding short circuit (current harmonic distortion rate > 8%)

[0067] ⑥ Sealing failure (pressure fluctuation > ±10%)

[0068] When an anomaly is detected, perform hierarchical load reduction:

[0069] - First-level alarm (power reduced to 70%)

[0070] - Second-level protection (power reduced to 50%)

[0071] - Emergency shutdown (power < 30% for 5 seconds)

[0072] Use wavelet packet decomposition to extract feature vectors, with classification accuracy ≥ 92%.

[0073] The working principle of the present invention is as follows: Based on the principle of multidisciplinary collaborative design, the present invention achieves high-efficiency fluid transportation through structural innovation and intelligent control. Its working principle can be divided into four major systems:

[0074] 1. Dual-driving force system

[0075] Two rim-type motors 3 with symmetrical distribution are used to form a double-stator drive structure or a water-cooled structure, and achieve differential frequency operation of 0.1 - 5 Hz through a vector control module. The hollow shaft of the motor forms a keyless connection with the impeller 4 through a conical positioning boss with a taper of 1:10, and laser welding ensures zero backlash in power transmission. The differential frequency operation of the dual motors can form a composite eddy current, which, in cooperation with the forward-swept three-dimensional twisted blades (NACA64 airfoil), generates axial-radial composite flow, increasing the head by more than 15%. An internal non-contact torque sensor monitors the load change in real time, and a sampling frequency of 1 kHz ensures the dynamic response accuracy.

[0076] 2. Fluid optimization system

[0077] The double-suction pipe is designed with a 15° - 25° oblique angle in combination with a radial flow guide groove, enabling the medium to form a spiral pre-whirl flow and reducing the inlet turbulent loss. The Venturi outlet pipe 15 efficiently converts kinetic energy into pressure energy through a throat diameter ratio of 1:1.2 - 1.5, increasing the throat flow velocity by 30%. The spiral cooling flow channel uses a design with a 6% decreasing cross-sectional area, and in cooperation with the turbulence intensifying ribs, forms a pressure gradient cooling, keeping the motor temperature rise within 45K.

[0078] 3. Structure strengthening system

[0079] The integrally cast cavity (coaxiality ≤ 0.05 mm) and the titanium alloy bolt group (pre-tightened with 25 - 35 N·m) form a rigid main frame. The rubber-metal laminated damper is distributed with a circumferential gradient stiffness, effectively attenuating broadband vibration. The Al2O3-ZrO2 composite ceramic coating (0.3 mm) and the heat-conducting silicone grease containing boron nitride form a double thermal protection system, enabling the shell 1 to withstand a temperature of 300°C.

[0080] 4. Intelligent control system

[0081] The integrated control box realizes multi-unit networking through the CAN bus, and the pressure feedback unit (with a response of ≤10 ms) automatically adjusts the differential frequency parameters. The fault diagnosis algorithm is based on FFT spectrum analysis, which can identify 5 types of typical abnormal vibrations (such as bearing wear, cavitation, etc.) and trigger hierarchical load reduction protection. The power of the dual motors is intelligently matched in the range of 30%-70% to ensure the non-stop continuous operation of the system.

[0082] Through the three-dimensional coordination of precise structure, thermodynamic optimization and intelligent control, the invention achieves ultra-high performance with an energy efficiency ratio ≥85% and MTBF > 30,000 hours, and is particularly suitable for precise fluid control under high-temperature and high-pressure working conditions.

Claims

1. A highly integrated electric pump, comprising a housing (1), a housing cover (2), a rim-type motor (3) and an impeller (4), characterized in that: The housing (1) is integrally cast to form two symmetrically distributed power installation cavities (11) and a central impeller installation cavity (12), and the three cavities are coaxial; Two rim-type motors (3) are press-fitted into the power installation cavities (11) with interference. The end of the hollow shaft of the rim-type motor (3) is provided with a conical positioning boss, and the two port rings of the impeller (4) are connected by keys; The first suction pipe (13) and the second suction pipe (14) extend obliquely from both sides of the housing.

2. The electric pump according to claim 1, wherein: The housing cover (2) is locked by a star-arranged bolt group with adjustable pre-tightening force, and the bolt group includes a plurality of alloy bolts evenly distributed along the circumference.

3. The electric pump according to claim 1, wherein: For the rim-type motor (3), a water-cooling structure is adopted between the stator core and the inner wall of the housing.

4. The electric pump according to claim 1, wherein: The flanges of the first suction pipe (13) and the second suction pipe (14) are integrally cast and merged into one suction pipe.

5. The electric pump according to claim 1, characterized in that: The impeller (4) adopts forward-swept three-dimensional twisted blades, the leading edge of the blade is of NACA64 airfoil type, and the taper of the hub conical interface is 1:

10.

6. The electric pump according to claim 1, characterized in that: The bottom of the power installation cavity (11) is provided with a spiral cooling flow channel, and the cross-sectional area of the flow channel decreases from the inlet to the outlet.

7. The electric pump according to claim 1, characterized in that: A non-contact torque sensor is embedded in the hollow shaft of the rim-type motor (3).

8. The electric pump according to claim 1, characterized in that: The top of the housing (1) is integrated with an intelligent control box, which includes: a dual-motor vector control module, a pressure feedback adjustment unit and a CAN bus interface.

9. The electric pump according to claim 8, characterized in that: The control box is built-in with a fault diagnosis algorithm, which can identify more than 5 abnormal vibration spectra and trigger the load reduction protection of the corresponding motor power.

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