Insulation type electronic water pump structure

Abstract

The utility model discloses an insulation type electronic water pump structure which comprises a pump shell, a water pump rear cover, a rotor, a stator, a controller and an IPM module, the rotor and the stator are both arranged in a pump cavity of the pump shell, the water pump rear cover is installed at the rear end of the pump shell, and a control chamber used for containing the controller and the IPM module is formed between the pump shell and the water pump rear cover. A rotor tank is arranged in a pump cavity of the pump shell and divides the pump cavity of the pump shell into a wet cavity and a dry cavity, the rotor is rotationally arranged in the wet cavity, an impeller is arranged at the front end of the rotor, and the stator is located in the dry cavity and arranged on the outer wall of the rotor tank in a sleeving mode. The novel electronic water pump structure with the medium insulated from the shell is excellent in insulation performance, heat dissipation performance and structural stability, and has remarkable advantages compared with the prior art.

Description

Technical Field

[0001] This utility model relates to the field of electronic water pump technology, specifically to an insulated electronic water pump structure. Background Technology

[0002] The increase in coolant conductivity is a significant issue during fuel cell operation. Increased conductivity leads to premature failure of the ion filter, impacting proton exchange efficiency and significantly reducing battery life. Furthermore, increased conductivity reduces system insulation, particularly in hydrogen fuel cell systems where the coolant carries a voltage potentially exceeding 300V. This not only affects system stability but also poses serious safety hazards. Therefore, fuel cell companies have imposed stringent requirements on the insulation performance between the coolant and the outer casing.

[0003] As a key component of fuel cell cooling systems, electric water pumps use brushless DC motors to drive impellers to rotate, meeting the cooling system's requirements for flow rate and head. However, current electric water pumps on the market have many shortcomings in terms of insulation and heat dissipation.

[0004] The first mainstream solution uses magnetic transmission, which can completely isolate the liquid from the motor chamber. However, the heat generated by the control board and motor is mainly dissipated by air cooling. The heat dissipation effect is greatly affected by the ambient temperature, especially in high-temperature environments, where the heat dissipation effect is greatly reduced.

[0005] The second approach uses a tank structure to isolate the motor's rotor and stator, allowing liquid from the cooling pipes to enter the tank, with the rotor submerged in the liquid. However, as the water pump power increases, the heat generated by the PCBA also rises, and using air cooling for heat dissipation is not ideal.

[0006] The third approach also uses a tank structure, but creates a pressure difference by drilling a through hole in the motor shaft, using water flow for cooling. While this method provides better heat dissipation for the control board, it fails to effectively insulate the medium from the casing. In recent years, although some products have attempted to achieve insulation through surface treatment, this method not only has poor insulation reliability but also carries the risk of perforation, high processing costs, and low yield. Utility Model Content

[0007] The technical problem to be solved by this utility model is to overcome the above-mentioned technical defects and provide an insulated electronic water pump structure.

[0008] To solve the above-mentioned technical problems, the technical solution provided by this utility model is as follows: an insulated electronic water pump structure, including a pump casing, a water pump rear cover, a rotor, a stator, a controller, and an IPM module. The rotor and stator are both located in the pump cavity of the pump casing. The water pump rear cover is installed at the rear end of the pump casing, and a control chamber for placing the controller and IPM module is formed between the pump casing and the water pump rear cover. A rotor tank is provided in the pump cavity of the pump casing, and the rotor tank divides the pump cavity of the pump casing into a wet cavity and a dry cavity. The rotor rotates in the wet cavity, and an impeller is provided at the front end of the rotor. The stator is located in the dry cavity and is sleeved on the outer wall of the rotor tank.

[0009] Preferably, the pump casing includes a volute, a motor housing, and a control chamber housing. The end of the volute near the wet chamber is connected to the rotor tank and the motor housing in sequence by screws and a sealing ring. The end of the motor housing away from the rotor tank is connected to the control chamber housing by screws and a sealing ring. The end of the control chamber housing away from the motor housing is connected to the pump rear cover by screws and a sealing ring.

[0010] Preferably, low-voltage connectors and high-voltage connectors are installed on the control room housing by screws, and the low-voltage connectors and high-voltage connectors are also connected to the controller inside the control room via wiring harnesses.

[0011] Preferably, a rotor tank end cover is installed at the end of the rotor tank away from the volute by screws, and a thermally conductive insulating gasket is attached between the rotor tank end cover and the control room outer shell.

[0012] Preferably, the rotor tank surface is provided with several vertical ribs, and the stator center hole is provided with a toothed groove that is nested and fitted with the vertical ribs.

[0013] Preferably, the rotor tank has several oblique ribs circumferentially arranged inside the end near the rotor tank end cover.

[0014] Preferably, a mounting bracket is provided inside the inlet of the vortex housing, and a support shaft is provided between the mounting bracket and the rotor tank end cover. The rotor is rotatably mounted on the support shaft via a graphite bearing.

[0015] Preferably, a thrust plate and a rubber pad are also fitted on the support shaft between the mounting bracket and the graphite bearing.

[0016] Preferably, the mounting bracket includes a mounting part and a plurality of connecting plates radially connected to one end of the mounting part. The end of the mounting part away from the connecting plates is provided with mounting holes for mounting the support shaft. The end of the connecting plates away from the mounting part is connected to the inner wall of the volute inlet, and a flow channel for the flow medium to pass through is formed between two adjacent connecting plates.

[0017] The advantages of this invention compared to existing technologies are as follows: First, through its innovative rotor tank design, this application not only achieves effective separation of the pump chamber but also ensures the insulation performance between the wet and dry chambers, thereby avoiding the risk of short circuits caused by media leakage in electronic components. This design fundamentally solves the problem of poor insulation performance in existing electronic water pumps. Furthermore, coolant can enter the rotor tank to effectively cool the rotor inside, while the stator tank effectively cools the assembled stator through heat conduction.

[0018] Secondly, the combined use of the rotor tank end cap and the thermally conductive insulating gasket in this application not only improves the heat dissipation performance of the electric water pump but also ensures the stable operation of the controller and IPM module in high-temperature environments. This improvement effectively overcomes the problems of poor heat dissipation and easy overheating damage of electronic components in the prior art.

[0019] Furthermore, the ingenious design of vertical and diagonal ribs in this application not only enhances the structural strength of the rotor tank but also improves the accuracy and stability of stator installation. This innovative design makes the electric water pump operate more smoothly at high speeds, reducing noise and vibration.

[0020] In summary, the novel electronic water pump structure with insulation between the medium and the housing proposed in this application exhibits excellent performance in terms of insulation, heat dissipation, and structural stability, demonstrating significant advantages over existing technologies. These advantages make the electronic water pump of this application more suitable for various complex working environments, providing a more reliable and efficient solution for fields such as automotive electronics and industrial cooling. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the external structure of an insulated electronic water pump structure according to this application.

[0022] Figure 2 This is a schematic diagram of the internal structure of an insulated electronic water pump according to this application.

[0023] Figure 3 This is an enlarged schematic diagram of the rotor tank structure with the rotor tank end cover removed in this application.

[0024] Figure 4 This is a front view of the internal structure of the rotor tank near the end cap of the rotor tank in this application.

[0025] Figure 5 This is an enlarged schematic diagram of the rotor tank end cover in this application.

[0026] As shown in the figure: 1. Pump casing, 101. Volute casing, 102. Motor casing, 103. Control room casing, 2. Pump rear cover, 3. Rotor, 4. Stator, 5. Controller, 6. IPM module, 7. Control room, 8. Rotor tank, 9. Impeller, 10. Low-pressure connector, 11. High-pressure connector, 12. Rotor tank end cover, 13. Thermally conductive insulating gasket, 14. Vertical rib, 15. Diagonal rib, 16. Mounting bracket, 161. Mounting part, 162. Connecting plate, 17. Support shaft, 18. Graphite bearing, 19. Thrust plate, 20. Rubber pad. Detailed Implementation

[0027] The present invention will now be described in further detail with reference to the accompanying drawings.

[0028] The specific embodiments of this utility model will be further described below with reference to the accompanying drawings. Identical components are indicated by the same reference numerals.

[0029] It should be noted that the terms “front,” “back,” “left,” “right,” “up,” and “down” used in the following description refer to the directions shown in the attached diagram, while the terms “inside” and “outside” refer to the directions toward or away from the geometric center of a specific component, respectively.

[0030] To make the content of this utility model easier to understand, the technical solutions in the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings.

[0031] See attached document Figure 1 -Appendix Figure 2An insulated electronic water pump structure includes a pump casing 1, a pump rear cover 2, a rotor 3, a stator 4, a controller 5, and an IPM module 6. The rotor 3 and stator 4 are both located within the pump cavity of the pump casing 1. The pump rear cover 2 is installed at the rear end of the pump casing 1, forming a control chamber 7 between the pump casing 1 and the pump rear cover 2 for housing the controller 5 and the IPM module 6. A rotor tank 8 is located within the pump cavity of the pump casing 1, dividing the pump cavity into a wet cavity and a dry cavity. The rotor 3 rotates within the wet cavity, and an impeller 9 is located at the front end of the rotor 3. The stator 4 is located within the dry cavity and is fitted onto the outer wall of the rotor tank 8. This electronic water pump structure mainly includes key components such as the pump casing 1, pump rear cover 2, rotor 3, stator 4, controller 5, and IPM module 6. The rotor 3 and stator 4 are cleverly positioned within the pump cavity of the pump casing 1, forming a complete motor drive system. The pump rear cover 2 is securely mounted on the rear end of the pump casing 1, together forming a control chamber 7 to house the controller 5 and the IPM module 6. Notably, a rotor tank 8 is cleverly designed within the pump chamber of the pump casing 1, acting as a barrier to divide the pump chamber into two independent spaces: a wet chamber and a dry chamber. The rotor 3 rotates flexibly within the wet chamber, and its front end is equipped with an impeller 9 to drive the circulation of coolant. The stator 4 sits firmly within the dry chamber and is tightly fitted onto the outer wall of the rotor tank 8.

[0032] In this technical solution, the pump casing 1 adopts a split design, comprising three main parts: a volute casing 101, a motor housing 102, and a control chamber housing 103. The end of the volute casing 101 closest to the wet chamber is tightly connected to the rotor tank 8 and the motor housing 102 sequentially using precision screws and sealing rings, ensuring the sealing and stability within the pump chamber. The other end of the motor housing 102 is connected to the control chamber housing 103 in the same manner. The end of the control chamber housing 103 forms a perfect closure with the pump rear cover 2, constituting a robust control chamber 7. This application also features specially designed low-voltage connectors 10 and high-voltage connectors 11 on the control chamber housing 103. These connectors are securely mounted to the control chamber housing 103 with screws and are tightly connected to the controller 5 inside the control chamber 7 via wiring harnesses, providing a stable power supply for the device.

[0033] In one specific embodiment, refer to the appendix. Figure 3 -Appendix Figure 5A rotor tank end cap 12 is screwed onto the end of the rotor tank 8 furthest from the volute 101. This end cap 12 not only seals the rotor tank 8 but also has a thermally conductive insulating gasket 13 attached between it and the control chamber housing 103. This thermally conductive insulating gasket 13 not only ensures the insulation performance of the electric water pump but also effectively transfers the low temperature carried by the low-temperature medium flowing inside the rotor tank 8 to the control chamber housing 103 through its excellent thermal conductivity. This significantly reduces the temperature of the control chamber housing 103, thus effectively cooling the controller 5 and IPM module 6 mounted on it. The rotor tank end cap 12 is made of metal, further eliminating the problem of conductivity leakage and enhancing the safety and reliability of the electric water pump.

[0034] In another embodiment, refer to the appendix Figure 3 Furthermore, this application also cleverly incorporates a ring of vertical ribs 14 on the surface of the rotor tank 8. These ribs 14 not only enhance the structural strength of the rotor tank 8 but also form a perfect nested fit with the toothed grooves in the center hole of the stator 4. This design not only simplifies the installation process of the stator 4 but also ensures the stability and accuracy of the stator 4 within the pump chamber. Additionally, refer to the attached... Figure 4 The rotor tank 8 is also designed with a ring of diagonal ribs 15 near the rotor tank end cover 12. The presence of these diagonal ribs 15 enables the rotor tank 8 to better withstand the pressure from the rotor tank end cover 12, thereby further improving the stability and durability of the entire rotor component.

[0035] Please refer to the appendix again. Figure 1 and appendix Figure 2 Within the inlet of the volute 101, the smooth rotation of the rotor 3 is achieved through the cooperation of the mounting bracket 16, the support shaft 17, and the graphite bearing 18. The thrust disc 19 and the rubber pad 20 further enhance the stability and reliability of the rotor 3 during rotation. The design of the mounting bracket 16 not only provides a mounting position for the support shaft 17 but also, through its radially connected connecting plates 162, forms flow channels between adjacent connecting plates 162 for the passage of the fluid medium, ensuring smooth flow of the coolant.

[0036] Working Principle: After the electric water pump is connected to the DC power supply, the DC brushless motor starts to work. Current is supplied to the stator 4 through the controller 5 and IPM module 6, generating a rotating magnetic field. The rotor 3, being positioned opposite the stator 4 within the pump chamber of the pump casing 1, begins to rotate under the influence of the rotating magnetic field. The rotation of the rotor 3, through the impeller 9 at its front end, drives the coolant to flow in the wet chamber within the pump chamber. This flow ensures effective circulation of the coolant, and the design of the rotor tank 8 allows the coolant to enter its interior. The flow of coolant within the rotor tank 8 not only effectively cools the moving parts such as the rotor 3, but also transfers the low temperature to the control chamber shell 103 through the rotor tank end cap 12 installed at the end of the rotor tank 8 away from the volute 101 and the thermally conductive insulating gasket 13 attached between the rotor tank and the control chamber shell 103. Since the rotor tank end cover 12 is made of metal, it has good thermal conductivity and can effectively reduce the temperature of the control chamber shell 103, thereby cooling the controller 5 and IPM module 6 installed on the control chamber shell 103, improving the overall heat dissipation performance and insulation effect.

[0037] The vertical ribs 14 on the surface of the rotor tank 8 not only enhance the structural strength of the rotor tank 8, but also enable accurate installation and positioning of the stator 4 through the nested engagement with the toothed grooves of the center hole of the stator 4. At the same time, the inclined ribs 15 provided inside the rotor tank 8 near the rotor tank end cover 12 enhance the rotor tank 8's ability to withstand the force exerted by the rotor tank end cover 12, thereby improving the stability of the entire rotor component.

[0038] In summary, this application achieves the circulation of coolant by driving the impeller to rotate using the DC brushless motor of the electronic water pump, and through the design of the rotor tank 8 and its related components, it achieves effective cooling and insulation protection for moving parts such as the rotor 3, as well as the controller 5 and IPM module 6, thereby improving the safety and reliability of the fuel cell system.

[0039] The present invention and its embodiments have been described above. This description is not restrictive, and the accompanying drawings are only one embodiment of the present invention; the actual structure is not limited thereto. In conclusion, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the inventive spirit of the present invention, such designs should fall within the protection scope of the present invention.

Claims

1. An insulated electronic water pump structure, comprising a pump housing (1), a pump rear cover (2), a rotor (3), a stator (4), a controller (5), and an IPM module (6), wherein the rotor (3) and the stator (4) are both disposed within the pump cavity of the pump housing (1), and the pump rear cover (2) is installed at the rear end of the pump housing (1), forming a control chamber (7) between the pump housing (1) and the pump rear cover (2) for housing the controller (5) and the IPM module (6), characterized in that, The pump chamber of the pump casing (1) is provided with a rotor tank (8), and the rotor tank (8) divides the pump chamber of the pump casing (1) into a wet chamber and a dry chamber. The rotor (3) is rotatably located in the wet chamber and the front end of the rotor (3) is provided with an impeller (9). The stator (4) is located in the dry chamber and is sleeved on the outer wall of the rotor tank (8).

2. The insulated electronic water pump structure according to claim 1, characterized in that, The pump casing (1) includes a volute casing (101), a motor housing (102), and a control chamber housing (103). The end of the volute casing (101) near the wet chamber is connected to the rotor tank (8) and the motor housing (102) in sequence by screws and sealing rings. The end of the motor housing (102) away from the rotor tank (8) is connected to the control chamber housing (103) by screws and sealing rings. The end of the control chamber housing (103) away from the motor housing (102) is connected to the pump rear cover (2) by screws and sealing rings.

3. The insulated electronic water pump structure according to claim 2, characterized in that, Low-voltage connectors (10) and high-voltage connectors (11) are mounted on the outer shell (103) of the control room by screws. The low-voltage connectors (10) and high-voltage connectors (11) are also connected to the controller (5) inside the control room (7) by wiring harnesses.

4. The insulated electronic water pump structure according to claim 2, characterized in that, The rotor tank (8) is fitted with a rotor tank end cap (12) by screws at the end away from the volute (101), and a thermally conductive insulating gasket (13) is attached between the rotor tank end cap (12) and the control room outer shell (103).

5. The insulated electronic water pump structure according to claim 4, characterized in that, The rotor tank (8) has several vertical ribs (14) around its surface, and the stator (4) has a toothed groove in the center hole that is nested and engaged with the vertical ribs (14).

6. The insulated electronic water pump structure according to claim 5, characterized in that, The rotor tank (8) has several oblique ribs (15) circumferentially arranged inside one end near the rotor tank end cap (12).

7. The insulated electronic water pump structure according to claim 4, characterized in that, The inlet of the vortex shell (101) is provided with a mounting bracket (16), and a support shaft (17) is provided between the mounting bracket (16) and the rotor tank end cover (12). The rotor (3) is rotatably mounted on the support shaft (17) through a graphite bearing (18).

8. The insulated electronic water pump structure according to claim 7, characterized in that, The support shaft (17) is also fitted with a thrust plate (19) and a rubber pad (20) located between the mounting bracket (16) and the graphite bearing (18).

9. An insulated electronic water pump structure according to claim 7 or 8, characterized in that, The mounting bracket (16) includes a mounting part (161) and a plurality of connecting plates (162) radially connected to one end of the mounting part (161). The end of the mounting part (161) away from the connecting plate (162) is provided with a mounting hole for mounting the support shaft (17). The end of the connecting plate (162) away from the mounting part (161) is connected to the inner wall of the inlet of the volute (101), and a flow channel for the flow medium to pass through is formed between two adjacent connecting plates (162).

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