Pump assembly

Abstract

The invention is a pump assembly (1) for a cooling system of an operating assembly of a vehicle, the pump assembly extending relative to an axis (X-X) and comprising: i) a housing assembly (2) comprising a housing body (21) and an auxiliary body (22) defining a dry chamber (201) and a wet chamber (202); ii) an electric motor assembly (4) comprising a stator (41) housed in the dry cavity (201) and a rotor (42) housed in the wet cavity (202); iii) an impeller assembly (3) housed in the wet chamber (202), comprising a blade body (30) and a control body (35) in which the rotor (42) is housed at least partially; iv) a shaft set (5), the majority of which is housed in the wet chamber (202), around which the impeller assembly (3) rotates, the shaft set comprising: a shaft (50) extending along an axis (X-X), comprising a free end (501) and a fixed end (500) engaged with the housing assembly (2); a head (51) positioned at the free end (501) projecting radially from the shaft (50) to provide an axial abutment against axial movement of the impeller assembly (3). The shaft (50) and the head (51) are in a single body. The shaft (50) extends in a cantilevered manner along the axis (X-X) from the housing assembly (2) to the head (51) by a shaft length (L), and the head (51) has a head height (l) along the axis (X-X); the ratio of the shaft length (L) to the head height (l) is between 10 and 25, preferably between 15 and 20.

Description

Technical Field

[0001] This invention relates to a pump assembly for a vehicle cooling system. Background Technology

[0002] In this disclosure, the term "vehicle" refers to any means of transport, without limitation of type or size, i.e., motor vehicle or articulated van.

[0003] In other words, the present invention relates to the automotive field, and more specifically, to a thermal management system for vehicle operating components or multiple operating systems.

[0004] Specifically, in this disclosure, "operating component" refers to a part or a specific group of parts for performing a certain operation necessary for the movement of the vehicle. In a preferred embodiment, "operating component" includes, for example, a heat-absorbing, electric, or hybrid motor assembly. In further structural variations, "operating component" includes other mechanical and electric vehicle components included in the vehicle, such as a transmission assembly, and such as a "battery assembly" or "electric motor assembly."

[0005] In the prior art, several implementations of pump assemblies for cooling systems of vehicle operating components are known, distinguished by their actuation type.

[0006] Specifically, the pump assembly of the present invention is suitable for electrically actuated components. In other words, the pump assembly of the present invention includes at least one electric motor that controls the rotational movement of an impeller assembly contained therein, thereby controlling the movement of a cooling liquid flowing in a cooling system to which the pump assembly is fluidly connected.

[0007] In particular, "cooling liquid" is a water-based liquid, such as a solution comprising water and ethylene glycol.

[0008] Various technical solutions for pump assemblies, including those with electric motors and electric drive units, are known, in which the rotor is "wet," i.e., housed in the hydraulic section of the pump assembly, such that the rotor is precisely cooled by cooling liquid moved by the impeller assembly.

[0009] In particular, the implementation of the pump assembly is known, wherein the impeller assembly and the rotor rotate freely relative to a fixed shaft, wherein the fixed shaft has a cantilever in the wet chamber.

[0010] Typical problems with this implementation involve vibrations in the components and noise generated when the pump assembly is actuated. Summary of the Invention

[0011] Therefore, the object of the present invention is to provide a pump assembly for a cooling system of operating components of a vehicle, which solves this typical problem of the prior art.

[0012] This objective is achieved by the pump assembly according to claim 1. Its dependent claims relate to preferred structural variations with further advantages. Attached Figure Description

[0013] The object of the invention will now be described in detail with reference to the accompanying drawings, in which: Figure 1 This is a side view of the pump assembly according to the present invention; Figure 2' and Figure 2'' The same cross-sectional view of the pump assembly as described in claim 1 is shown; Figure 2a This is an enlarged view of the area in Figure 2; Figure 3 It is a cross-sectional perspective view of some components assembled by co-molding, namely, the impeller assembly, the rotor, and the cylindrical bushing; Figure 3 a is Figure 3 A perspective view of a single part of a component; Figure 4 yes Figure 1 A perspective view of individual parts of some components of the pump assembly. Detailed Implementation

[0014] In the above figures, reference numeral 1 generally indicates a pump assembly for a cooling system used in the operating components of a vehicle.

[0015] The pump assembly 1 of the present invention extends longitudinally relative to the axis XX.

[0016] According to the present invention, the pump assembly 1 includes a housing assembly 2.

[0017] Preferably, the housing assembly 2 is adapted to house at least most of the components of the pump assembly 1 of the present invention, as described below.

[0018] Preferably, the housing assembly 2 is fluidly connected to a pipe of the cooling system in which the cooling liquid moved by the pump assembly 1 flows.

[0019] The housing assembly 2 includes a housing body 21 and an auxiliary body 22.

[0020] The housing assembly 2 defines a dry chamber 201 and a wet chamber 202 in the connecting portion between the housing body 21 and the auxiliary body 22. In other words, coolant can enter the wet chamber 202 without restriction, while coolant is prevented from entering the dry chamber 201, which is sealed and isolated from the wet chamber 202.

[0021] The wet cavity 202 includes a central portion 202' along the axis XX, and the dry cavity 201 includes an annular portion 201' surrounding the central portion 202'.

[0022] In other words, according to the preferred embodiment, the housing body 21 and the auxiliary body 22 are joined together in a sealing manner. Preferably, a suitable gasket is provided on the housing body 21 or the auxiliary body 22.

[0023] According to a preferred embodiment, the housing assembly 2 can be assembled with suitable components of a vehicle to form system fluid conduits within the vehicle, for example, a suitable system that houses operating components and / or valve assemblies. These components, for example, include specific spiral sections in which the pump assembly 1 operates.

[0024] According to a preferred embodiment, the housing assembly 2 includes a bottom wall.

[0025] Preferably, the bottom wall 220 is included in the auxiliary body 22.

[0026] Preferably, the bottom wall is contained within the housing body 21.

[0027] According to a preferred embodiment, the bottom wall 220 includes a chassis made of a metallic material.

[0028] Preferably, the bottom wall includes a support collar 225 protruding along axis XX in the central portion 202'.

[0029] According to a preferred embodiment, the housing body 21 is made of a metallic material, such as an aluminum alloy.

[0030] According to a preferred embodiment, the housing body 21 is made of a plastic material, such as PPS.

[0031] According to a preferred embodiment, the auxiliary body 22 is made of a plastic material, such as PPS.

[0032] According to a preferred embodiment, the bottom wall 220 includes a disc-shaped portion made of a metallic material.

[0033] Preferably, the support collar 225 is made of a metallic material, such as aluminum.

[0034] According to another preferred embodiment, housing assembly 2 includes a volute body of a pipe fluidly connected to the cooling system.

[0035] Preferably, the volute body is adapted to engage with the housing body 21 and / or the auxiliary body 22. Preferably, in the connection between the volute body and the housing body 21 and / or the auxiliary body 22, the housing assembly 2 defines an impeller portion 202'' at the top of the wet cavity 202, in which the impeller 3 (described below) is accommodated. Specifically, the wet cavity 202 in which the cooling liquid flows is integrally defined in the connection between the volute body and the housing body 21 and / or the auxiliary body 22.

[0036] According to a preferred embodiment, the volute body is made of a plastic material, such as PPS.

[0037] As described above, the pump assembly 1 includes an impeller assembly 3 housed in the wet chamber 202.

[0038] The impeller assembly 3 includes a blade body 30 housed in the impeller section 202''.

[0039] According to a preferred embodiment, such as the one shown in the accompanying drawings, the pump assembly 1 further includes a blade cover 300 that can be assembled onto the blade body 30 of the impeller assembly 3. Depending on the shape of the blade body 3, the blade cover 300 may be a single piece (i.e., embedded in the impeller assembly 3) or a separate component that engages with the blade body 3.

[0040] Preferably, the impeller assembly 3 is made of plastic material, preferably PPS.

[0041] In addition, the pump assembly 1 includes an electric motor assembly 4, which includes a stator 41 housed in the dry chamber 201 and a rotor 42 housed in the wet chamber 202.

[0042] The stator 41 is housed in the annular portion 201' and the rotor 42 is housed in the central portion 202'.

[0043] Preferably, the rotor 42 includes a rotor body 420.

[0044] Preferably, the rotor body 420 includes a plurality of stacked layered elements.

[0045] Preferably, the rotor 42 includes rotor poles 421, for example, including specific magnetic elements.

[0046] According to a preferred embodiment, the layered elements define a suitable housing in their stack, within which the rotor poles 421 are positioned.

[0047] According to the present invention, the pump assembly 1 includes a shaft assembly 5 mainly housed in the wet chamber 202, the shaft assembly comprising: - Shaft 50, extending along axis XX in central portion 202', includes free end 501 and fixed end 500 that engages with housing assembly 2; - The head 51, located at the fixed end 501, protrudes radially from the shaft 50 to provide an axial abutment to resist axial movement of the impeller assembly 3.

[0048] According to the present invention, the shaft 50 and the head 51 are made as one piece.

[0049] According to a preferred embodiment, the pump assembly 1 includes a cylindrical bushing 7 extending along axis XX, which is freely rotatable and externally engages with rotor 42 and impeller assembly 3.

[0050] According to a preferred embodiment, the pump assembly 1 has a geometry such that the rotation of the rotor 42 corresponds to the rotation of the cylindrical bushing 7 and the impeller assembly 3 on the shaft 5.

[0051] Preferably, the cylindrical bushing 7 is made of a metallic material, such as sintered steel with graphite.

[0052] Preferably, the cylindrical bushing 7 is made of pressed graphite.

[0053] Preferably, the cylindrical bushing 7 is made of graphite-filled resin.

[0054] Preferably, the rotor 42 is assembled onto the cylindrical bushing 7. Then the impeller assembly 3 is molded onto this component.

[0055] Preferably, the rotor 42 and the cylindrical bushing 7 are joined together by geometric interference. Preferably, the rotor 42 and the cylindrical bushing 7 are integrally connected to each other.

[0056] According to the present invention, the impeller assembly 3 includes a control body 35 extending longitudinally from the blade body 30 along the axis XX.

[0057] Preferably, the control body 35 is engaged with the cylindrical bushing 7 and the rotor 42 to further secure them.

[0058] In other words, the impeller assembly 3 is co-molded with the cylindrical bushing 7 and the rotor 42 to form a single “complex component” whose respective components are integrated with each other.

[0059] According to a preferred embodiment, the rotor 42 is positioned on the cylindrical bushing 7, and both are molded together with the impeller assembly 3 after being arranged in a suitable mold to obtain a "complex component". The "complex component" is then assembled onto the free-rotating shaft 50.

[0060] According to a preferred embodiment, the control body 35 extends radially from the cylindrical bushing 7 and at least partially accommodates the rotor 42.

[0061] According to a preferred embodiment, the cylindrical bushing 7 has an outer surface 71 adapted to facilitate engagement with the impeller assembly 3, for example, on both sides of the rotor 42. For example, the outer surface 71 has slots and / or rough portions.

[0062] According to a preferred embodiment, the pump assembly 1 includes at least one cooling conduit 6 suitable for the recirculation of cooling liquid. Preferably, the cooling liquid flows toward the blade element 30 in the cooling conduit 6.

[0063] Preferably, the cooling pipe 6 extends substantially parallel to the axis XX.

[0064] Preferably, the cooling conduit 6 includes a rotor section 64 that runs through the rotor 42.

[0065] Preferably, the rotor segment 64 of the cooling conduit 6 extends into the rotor body 420. In other words, the layered element is shaped to present specific openings such that it defines the rotor segment 64 in the stack.

[0066] According to a preferred embodiment, the cooling duct 6 includes at least one impeller section 635', 635'' which traverses the impeller 3 in a manner aligned with the rotor section 64.

[0067] Preferably, the cooling duct 6 includes a first impeller section 635' and a second impeller section 635'' on opposite sides of the rotor section 64.

[0068] According to a preferred embodiment, impeller sections 635' and 635'' have a larger channel cross-section than rotor section 64.

[0069] According to a preferred embodiment, the pump assembly 1 includes a plurality of cooling pipes 6 spaced apart at equal angles.

[0070] Preferably, each cooling pipe 6 is located in a region radially close to the cylindrical bushing 7.

[0071] Preferably, each cooling pipe 6 is radially positioned between the cylindrical bushing 7 and the rotor pole 421.

[0072] According to a preferred embodiment, the pump assembly 1 further includes a gasket 9 axially positioned between the cylindrical bushing 7 and the head 51.

[0073] Preferably, the gasket 9 is adapted to minimize friction between the cylindrical bushing 7 and the head 51.

[0074] According to a preferred embodiment, the gasket 9 is made of a material selected from ceramic materials.

[0075] Preferably, the gasket 9 is made of aluminum oxide.

[0076] According to a preferred embodiment, the gasket 9 includes a radial slot 91 through which cooling liquid flows upward to the shaft 50.

[0077] Preferably, the gasket 9 includes a radial slot 91 on the upper surface facing the head 51.

[0078] Preferably, the gasket 9 includes a radial slot 91 on the lower surface facing the cylindrical bushing 7.

[0079] Preferably, at the free end 501 near the head 51, the shaft 50 has an annular groove 591 in which cooling liquid flows.

[0080] According to the present invention, the shaft 50 extends in a cantilever manner from the housing assembly 2 toward the head 51 by a shaft segment L along the axis XX.

[0081] Preferably, the shaft 50 has a shaft diameter D.

[0082] According to the present invention, the head 51 has a head height l along the axis XX.

[0083] Preferably, the head 51 has a head diameter d.

[0084] According to the present invention, the ratio of shaft length L to head height l is between 10 and 25.

[0085] Preferably, the ratio of shaft diameter D to head diameter d is between 0.4 and 0.8.

[0086] Preferably, the ratio of shaft length L to head height l is between 15 and 20.

[0087] Preferably, the ratio of shaft diameter D to head diameter d is between 0.5 and 0.7.

[0088] Preferably, the shaft length L is between 25 mm and 30 mm.

[0089] Preferably, the shaft diameter D is between 4 mm and 6 mm.

[0090] According to a preferred embodiment, the shaft length L extends from the support collar 225 to the head 51.

[0091] Preferably, the disc-shaped portion is made of metal, and the shaft 50 is also made of metal. Preferably, the shaft 50 and the disc-shaped portion are connected by force coupling.

[0092] According to a preferred embodiment, the pump assembly 1 having the aforementioned features undergoes a specific manufacturing method.

[0093] Specifically, the manufacturing method includes the step of co-molding the impeller assembly 3 with the rotor 42 and the cylindrical bushing 7.

[0094] According to a preferred embodiment, the invention also relates to the step of positioning the rotor 42 on the cylindrical bushing 7 and housing them together in a suitable mold in which the impeller assembly 3 and they are molded into a “complex component”.

[0095] Preferably, a suitable mold includes specific rod-shaped elements adapted to form segments of cooling channels.

[0096] Innovatively, the pump assembly achieves its intended purpose significantly by overcoming typical problems of existing technologies.

[0097] Advantageously, the pump assembly actually has an impeller assembly and a rotor housed in the same chamber, both of which are wetted by the cooling liquid.

[0098] Advantageously, cylindrical bushings and gaskets prevent friction and wear on the shaft.

[0099] Advantageously, the gasket also serves to prevent friction and wear between the bushing and the head.

[0100] Advantageously, the gasket is effectively lubricated by the cooling fluid. Advantageously, the shaft is effectively lubricated by the cooling fluid.

[0101] Advantageously, the pump assembly has a simple and defined positioning of the impeller assembly relative to the shaft of a shaft assembly fixed in a defined position.

[0102] Advantageously, cylindrical bushings are easy to manufacture and have a robust structure without slots, gaps and / or openings.

[0103] Advantageously, the pump assembly has a cantilevered impeller assembly, which requires no additional axial support other than a single fixed end of the shaft.

[0104] Advantageously, the pump assembly can be used in constructions with a volute body and in constructions that achieve a volute shape on other vehicle parts.

[0105] Advantageously, the pump assembly is quiet and has solutions to noise problems, such as those caused by improper positioning of the blade elements or by unwanted friction.

[0106] Advantageously, the pump assembly has a specific axial geometry.

[0107] Advantageously, the pump assembly, especially the shaft, has its own frequency to ensure reduced vibration and noise when the impeller assembly rotates.

[0108] Advantageously, the pump assembly has a simple construction.

[0109] Advantageously, the pump assembly is easy to assemble.

[0110] It is obvious that those skilled in the art may make changes to the invention described above to meet possible needs, and all such changes are included within the scope of protection defined by the appended claims.

Claims

1. A pump assembly (1) for a cooling system of a vehicle operating component, the pump assembly extending relative to an axis (XX) and comprising: i) Housing assembly (2) including housing body (21) and auxiliary body (22), wherein the housing assembly (2) defines a dry cavity (201) and a wet cavity (202) at the junction of the housing body (21) and the auxiliary body (22), wherein the wet cavity (202) includes a central portion (202') along the axis (XX), and the dry cavity (201) includes an annular portion (201') surrounding the central portion (202'); ii) Electric motor assembly (4), including a stator (41) housed in the annular portion (201') and a rotor (42) housed in the central portion (202'); iii) Impeller assembly (3), housed in the wet chamber (202), the impeller assembly including blade body (30) and control body (35), the rotor (42) being at least partially housed in the control body; iv) Shaft assembly (5), most of which is housed in the wet chamber (202), the impeller assembly (3) rotating about the shaft assembly, the shaft assembly comprising: - A shaft (50) extending along the axis (XX) in the central portion (202'), the shaft including a free end (501) and a fixed end (500) engaging with the housing assembly (2). - A head (51), positioned at the free end (501), the head protruding radially from the shaft (50) to provide axial abutment to prevent axial movement of the impeller assembly (3); The shaft (50) and the head (51) are located in a single body. The shaft (50) extends cantilevered along the axis (XX) from the housing assembly (2) toward the head (51) by a shaft length (L), wherein the head (51) has a head height (I) along the axis (XX), wherein the ratio of the shaft length (L) to the head height (I) is between 10 and 25, preferably between 15 and 20.

2. The pump assembly (1) according to claim 1, wherein, The shaft (50) has a shaft diameter (D) and the head has a head diameter (d), wherein the ratio of the shaft diameter (D) to the head diameter (d) is between 0.4 and 0.8, preferably between 0.5 and 0.

7.

3. The pump assembly (1) according to any one of the preceding claims, wherein, The housing assembly (2) includes a bottom wall and a support collar, the fixed end (500) being accommodated in the support collar, wherein the shaft length (L) extends from the support collar (225) to the head (51).

4. The pump assembly (1) according to any one of the preceding claims, wherein, The bottom wall includes a disc-shaped portion made of metal, and the shaft (50) is also made of metal, wherein the shaft (50) and the disc-shaped portion are connected by force connection.

5. The pump assembly (1) according to any one of the preceding claims includes a cylindrical bushing (7) extending along the axis (XX), the cylindrical bushing being rotatable and externally engaging with the rotor (42) and the impeller assembly (3).

6. The pump assembly (1) according to claim 5, wherein, The axial dimension of the cylindrical bushing (7) along the axis (XX) is substantially equal to the length of the axis (L).

7. The pump assembly (1) according to claim 5, comprising a gasket (9) positioned axially between the cylindrical bushing (7) and the head (51), wherein the gasket (9) is made of a material selected from ceramic materials.

8. The pump assembly (1) according to claim 7, wherein, The axial dimension of the cylindrical bushing (7) and the gasket (9) along the axis (XX) is substantially equal to the length of the axis (L).

9. The pump assembly (1) according to any one of claims 5 to 8, wherein, The rotor (42) is engaged with the cylindrical bushing (7) by means of force connection, for example.

10. The pump assembly (1) according to claim 9, wherein, The control body (35) extends radially relative to the cylindrical bushing (7) and at least partially accommodates the rotor.

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