Embedded electronic water pump for thermal management integrated module of electric vehicle

Abstract

The utility model discloses an embedded electronic water pump for a thermal management integrated module of an electric automobile. The embedded electronic water pump comprises a pump body sub-component, a motor body sub-component and a controller, the pump body component is provided with a motor rotor assembly, an impeller, a pump base, a waterproof supporting sleeve, a second sealing ring, a pump shell, a third sealing ring, a fourth sealing ring, a flow guide sleeve, a fifth sealing ring, a first bearing and a clamping ring. The motor body component and the controller are provided with a motor shell, a motor shell sealing gasket, an insulating end piece, a coil winding, a stator core, a fastening screw ring, a convergence disc wiring terminal, the controller, a power connector, a rear end cover, a first sealing ring, a stator core fixing screw and a third screw. The embedded electronic water pump is highly integrated with a new energy automobile heat management integrated module, the use number of cooling liquid loop pipelines, water valves and actuators in a heat management system is reduced, the arrangement space is saved, and the embedded electronic water pump is particularly suitable for an electric automobile heat management integrated module with higher modularization and integration requirements.

Description

Technical Field

[0001] This utility model belongs to the technical field of electric vehicle devices and accessories, specifically relating to an embedded electronic water pump for an integrated module of thermal management in electric vehicles. Background Technology

[0002] With the rapid development of the new energy vehicle industry, especially the increasing demands on the energy management of new energy vehicle thermal management systems due to the intelligent cockpit, power battery pack cooling system, and electric drive module cooling system, the requirements for thermal management systems in new energy vehicles are becoming increasingly stringent. The integrated modularization of the thermal management system is crucial for the vehicle's range, safety, and passenger comfort, especially for the integrated thermal management module in electric vehicles. The embedded electronic water pump is a key component in the integrated thermal management module of an electric vehicle, and its performance significantly affects the efficiency of the module. The embedded electronic water pump features high flow rate, high head, low noise, and reliable operation, making it an energy-saving, safe, and environmentally friendly high-tech device for the integrated thermal management module of electric vehicles. Furthermore, the embedded electronic water pump has a compact structure, good integration, saves space, is easy to assemble, and is easy to maintain.

[0003] Currently, most new energy vehicles on the market require accurate thermal management of the three-electric system (electric control, battery, and electric drive) and the cab under different operating conditions, and most of them adopt decentralized control. On the one hand, traditional pipe-connected electronic water pumps require more coolant circuit pipes, which also increases the space requirements for the entire thermal management system layout, increasing manufacturing and installation costs and hindering the precise control of the entire thermal management module. On the other hand, considering the different operating conditions of the vehicle, highly modular integration of embedded electronic water pumps, heat exchangers, electronic expansion valves, etc., through new assembly methods and processes can reduce the number of coolant circuit pipes, water valves, and actuators used, optimize fluid flow resistance design, reduce pressure loss, and avoid jamming of embedded electronic water pumps. Therefore, providing an embedded electronic water pump that can be used stably for a long time, has a simple assembly process, and lower cost, by completely separating the pump body components and the motor body components and integrating the water pump motor controller, not only meets the diverse needs of electric vehicles for thermal management integrated modules, but also has a broader market application prospect. Summary of the Invention

[0004] To address the problems of traditional pipe-connected electronic water pumps, the present invention aims to provide an embedded electronic water pump for an integrated thermal management module of electric vehicles. This embedded electronic water pump can meet the structural strength requirements of the embedded electronic water pump and the modular and integrated design requirements of the thermal management system, while achieving continuous and stable output of high flow rate, high head, and low noise, thus ensuring the efficient operation of the integrated thermal management module of the electric vehicle.

[0005] An embedded electronic water pump for an integrated thermal management module of an electric vehicle includes a pump body component, a motor body component, and a controller. The pump body component comprises a motor rotor assembly, an impeller, a pump base, a water-resistant support sleeve, a second sealing ring, a pump housing, a third sealing ring, a fourth sealing ring, a flow guide sleeve, a fifth sealing ring, a first bearing, and a retaining ring. The motor rotor assembly includes a second bearing, a molded part, a rotor magnetic ring, locking screws, a pump shaft, and a wave spring washer. The small end of the pump shaft is interference-fitted with the second bearing. The motor rotor assembly and the second bearing are then slidably fitted into the cavity of the water-resistant support sleeve and the bearing chamber at the bottom. The pump base is assembled onto the water-resistant support sleeve and fixed to it with three screws. The impeller insert on the impeller is interference-fitted onto the splined shaft at the large end of the pump shaft, with one end face of the impeller insert fitting against the top plane of the molded part. The impeller is then secured to the water-resistant support sleeve with two locking screws. The motor rotor assembly is connected and fixed, and then the wave spring washer is fitted onto the bearing position at the large end of the pump shaft. Similarly, bearing one and retaining ring are assembled into the bearing chamber in the internal cavity of the pump housing. Two rectangular sealing grooves are provided on the outer cylindrical surface of the pump housing, and sealing ring three and sealing ring four are respectively installed in the two rectangular sealing grooves. At the same time, an end face annular groove is provided on the large end face of the pump housing, and sealing ring two is installed inside the end face annular groove. The guide sleeve is fitted into the cavity inside the large end face of the pump housing and is flush with the large end face of the pump housing. A rectangular sealing ring groove is provided on the end face of the guide sleeve, and sealing ring five is installed inside the rectangular sealing ring groove. The pump housing and the related components assembled on it are slidably fitted into the end face of the water-proof support sleeve, so that the inner ring of bearing one is slidably connected to the bearing part at the large end of the pump shaft. Bearing one and bearing two are set as dust-free semi-ceramic deep groove ball bearings or dust-free engineering plastic deep groove ball bearings. The mechanical assembly of the pump body components is completed.

[0006] The motor body is divided into several components, including a motor housing, a motor housing gasket, insulating end plates, coil windings, a stator core, fastening screws, a busbar terminal block, a controller, a power connector, a rear end cover, a sealing ring, stator core fixing screws, and three screws. The outer circumference of the stator core has three evenly distributed screw through holes. Each tooth crown of the stator core has two auxiliary slots. An insulating end plate is mounted on each of the two end faces of the stator core, and the coil windings are wound on the insulating end plates. The busbar terminal block is connected and fixed to the coil windings. The controller has a power connector. The interior of the motor housing cavity has three evenly distributed threaded holes, which are matched and positioned with the three evenly distributed screw through holes on the stator core. The front end face of the motor housing has a sealing groove containing a motor housing gasket. The front end face of the motor housing also has six evenly distributed through holes. The rear end face of the motor housing has three bosses that fit into the rear end cover. The outer circumference of the motor housing... The motor housing has three evenly distributed threaded holes, which match the three oblong holes on the fastening ring. The fastening ring also has three evenly distributed oblong holes on its end face and a full thread on its outer circumference. The inner ring of the fastening ring is nested on the steps of three bosses on the outer circumference of the motor housing. The rear end cover has an annular sealing groove on its outer circumference, containing a sealing ring. The rear end cover also has grooves that engage with the three bosses on the rear end face of the motor housing. The stator core and its related components are pre-positioned by aligning and fitting the three evenly distributed screw holes on the stator core and the three evenly distributed threaded holes inside the motor housing cavity. Then, three stator core fixing screws are used to connect and fix the stator core and its related components to the motor housing. Insulating and thermally conductive adhesive is applied to the mating surfaces of the stator core and the motor housing. This completes the mechanical assembly of the motor body components.

[0007] Assemble the water-proof support sleeve and its assemblies with the motor body components. The inner cylindrical surface of the bottom of the water-proof support sleeve transitions to the outer cylindrical surface of the bearing chamber at the bottom of the motor housing. Secure the water-proof support sleeve to the motor housing using two screws through two threaded holes. Connect and fix the controller to the rear cavity of the motor housing with screws. Weld the three-phase power leads on the busbar terminals to the controller's circuit board. Secure the rear cover to the motor housing using laser welding or ultrasonic welding at the riveted stop positions. Seal the power connector to the rear cover using laser welding or ultrasonic welding at the welded sealing port positions. Align the six through holes on the top plane of the water-proof support sleeve with the six screw through holes on the front face of the motor housing. Similarly, align the six threaded holes on the pump housing with the six screw through holes on the front face of the motor housing. Connect and fix the pump housing, water-proof support sleeve, and motor housing with six screws. This completes the assembly of the pump body components, motor body components, and controller.

[0008] The assembled embedded electric water pump is installed into the two stepped cavities pre-set in the thermal management integrated module. Sealing rings three and four, along with these two stepped cavities, create separate flow paths for the coolant. Sealing ring three, together with one of the stepped cavities pre-set in the thermal management integrated module, forms the inlet channel, and sealing ring four, together with the other stepped cavity pre-set in the thermal management integrated module, forms the outlet channel. The embedded electric water pump is then pressed against the end face of the pre-set cavity in the thermal management integrated module by rotating the fastening ring. Finally, three screws are used to connect and fix the fastening ring and the motor housing inside the thermal management integrated module. This mechanism is simple, compact, compatible, easy to assemble, and convenient to maintain.

[0009] The above-mentioned technical problem of this utility model is solved by the following technical solution:

[0010] An embedded electronic water pump for an integrated thermal management module of an electric vehicle is characterized by comprising: an impeller insert, a screw through hole one, a tooth profile fillet, a screw three, a riveted stop, an auxiliary groove, a rear end cover, a welded sealing port, a stator core fixing screw, a sealing ring one, a bearing one, a bearing two, a retaining ring, a fastening screw ring, a manifold terminal block, a controller, a power connector, a motor housing, a motor housing gasket, an insulating end piece, a coil winding, a stator core, a water-proof support sleeve, a sealing ring two, a threaded hole one, a threaded hole two, a cylindrical boss, a trapezoidal reinforcing rib, a rectangular reinforcing rib, a pump base, a countersunk hole one, a motor rotor assembly, an injection molded part, a rotor magnetic ring, a locking screw, an impeller, a pump shaft, a wave spring washer, an impeller blade bottom draft angle, an impeller blade misalignment angle, an impeller blade tooth pitch angle, an impeller blade length, an impeller blade helix angle, a pump housing, a sealing ring three, a sealing ring four, a flow guide sleeve, a sealing ring five, an inlet channel, an outlet channel, a fluid flow direction, and a threaded hole six.

[0011] The motor rotor assembly includes the second bearing, the injection-molded part, the rotor magnetic ring, the locking screw, the pump shaft, and the wave spring washer. The large end of the pump shaft has a spline on its cylindrical surface that is interference-fitted with the impeller insert. The small end of the pump shaft is interference-fitted with the second bearing. The rotor magnetic ring and the pump shaft are injection-molded and fixed together via the injection-molded part. The top plane of the injection-molded part has two threaded holes corresponding to the locking screw. The pump base has the first countersunk hole and the inlet channel. The bottom of the pump base has an inner circular cavity that mates with the water-proof support sleeve. The rotor magnetic ring has two pole pairs. The first and second bearings are either dust-free semi-ceramic deep groove ball bearings or dust-free engineering plastic deep groove ball bearings.

[0012] The impeller includes the impeller insert, the screw through hole, the tooth profile fillet, the impeller blade bottom draft angle, the impeller blade misalignment angle, the impeller blade tooth pitch angle, the impeller blade length, and the impeller blade helix angle. The total number of blades on one side of the impeller is set to a range of 6 to 46, and the number of blades on both sides of the impeller is set to be equal. The impeller blade tooth pitch angle is set to be evenly distributed along the circumference of the impeller. The impeller blade misalignment angle is set to be the angle of relative angular displacement between the two sides of the impeller, ranging from 1.0° to 5.0°. The impeller blade length is set to... The value range is set to 0.40 to 0.60 times the radius of the impeller, and the helix angle of the impeller blade is set to 1.0° to 10.0°. The draft angle of the bottom of the impeller blade is set to an arc shape. The tooth profile fillet on the outer circumference of the impeller refers to the fillet of one edge of the blade facing away from the fluid flow direction. The inner cavity of the impeller insert is provided with splines for assembly error prevention. By optimizing the design of the impeller blade helix angle, the impeller blade tooth pitch angle, and the tooth profile fillet, the water control volume of each cavity formed by the impeller blades is increased, and the output flow rate of the embedded electronic water pump is further improved.

[0013] The waterproof support sleeve is provided with threaded hole one, threaded hole two, cylindrical boss, trapezoidal reinforcing rib, and rectangular reinforcing rib; a circular boss is provided at the center of the end face of the waterproof support sleeve, and the pump seat is assembled on the circular boss at the center of the end face of the waterproof support sleeve. The pump seat is connected and fixed to the waterproof support sleeve by three screws through the countersunk hole one provided by the pump seat and the threaded hole one provided by the waterproof support sleeve; the bottom of the inner cavity of the waterproof support sleeve is provided with a bearing chamber that slides with the bearing two, and two small threaded holes two are provided on the end face of the outer cylinder at the bottom of the waterproof support sleeve.

[0014] The pump housing is provided with the inlet channel, the outlet channel, the fluid flow direction, and the threaded hole six; the bearing chamber in the internal circular cavity of the pump housing is equipped with the bearing one and the retaining ring; the outer cylindrical surface of the pump housing is provided with two rectangular sealing grooves, and the two rectangular sealing grooves are respectively equipped with the sealing ring three and the sealing ring four; at the same time, the large end face of the pump housing is provided with an end face annular groove, and the sealing ring two is installed inside this end face annular groove; the flow guide sleeve is fitted with a transition fit inside the circular cavity of the large end face of the pump housing and is flush with the large end face of the pump housing; the end face of the flow guide sleeve is provided with a rectangular sealing ring groove, and the sealing ring five is installed inside this rectangular sealing ring groove.

[0015] The motor rotor assembly and the second bearing are slidably fitted into the circular cavity and the bearing chamber at the bottom of the water-proof support sleeve. The rectangular reinforcing rib and the auxiliary groove are assembled accordingly. The pump base is connected and fixed to the water-proof support sleeve using three screws through the countersunk hole one provided on the pump base and the threaded hole one provided on the water-proof support sleeve. The inner cavity of the impeller insert is press-fitted onto the spline shaft at the large end of the pump shaft. One end face of the impeller insert is in contact with the top plane of the injection molded part. The impeller is connected and fixed to the motor rotor assembly using two locking screws. The wave spring washer is then fitted onto the bearing position at the large end of the pump shaft. The pump housing and its related components are slidably fitted into the end face of the water-proof support sleeve, so that the inner ring of the first bearing is slidably connected to the bearing part at the large end of the pump shaft. The mechanical assembly of the pump body components is completed.

[0016] The stator core has three evenly distributed screw through holes on its outer circumference. The stator core has six tooth slots. Each tooth crown has two auxiliary slots, which are rectangular. The depth of the auxiliary slots ranges from 0.36 mm to 1.20 mm, and their width is equal to the slot width of the stator core. The motor housing has three evenly distributed threaded holes inside its circular cavity, which are matched and positioned with the three evenly distributed screw through holes on the stator core. A sealing groove is provided on the front end face of the motor housing. The sealing groove contains the motor housing sealing gasket. The front face of the motor housing has six evenly distributed through holes, and the rear face of the motor housing has three bosses that fit with the rear end cover. The outer circumference of the motor housing has three evenly distributed threaded holes that match the three oblong holes on the fastening screw. The end face of the fastening screw has three evenly distributed oblong holes, and the outer circumference of the fastening screw has a full thread. The inner ring of the fastening screw is nested on the steps of the three bosses on the outer circumference of the motor housing. The outer circumference of the steps of the rear end cover... The stator core has an annular sealing groove containing the sealing ring. The rear end cover also has grooves that engage with the three protrusions on the rear end face of the motor housing. An insulating end plate is mounted on each of the two end faces of the stator core. The coil winding is wound on the insulating end plate using a fractional-slot concentrated winding design. The insulating end plate is wound with single-layer copper enameled wire, and the coil winding is connected using a delta (Δ) connection. The busbar terminals are connected and fixed to the coil winding. The controller has a power connector. The stator core and its related components are then pre-positioned by aligning and fitting the three evenly distributed screw holes on the stator core with the three evenly distributed threaded holes inside the circular cavity of the motor housing. The stator core and its related components are then transitionally assembled into the circular cavity of the motor housing. Three stator core fixing screws are then used to connect and fix the stator core and its related components to the motor housing. Insulating and thermally conductive adhesive is applied to the assembly surface between the stator core and the motor housing to improve the heat dissipation and vibration resistance of the stator core and its components. This completes the mechanical assembly of the motor body components.

[0017] Assemble the waterproof support sleeve and its assemblies with the motor body components. The inner cylindrical surface of the bottom of the waterproof support sleeve transitions to the outer cylindrical surface of the bearing chamber at the bottom of the motor housing. Secure the waterproof support sleeve to the motor housing with two screws through the two threaded holes. Connect and fix the controller to the rear cavity of the motor housing with screws. Weld the three-phase power lead on the busbar terminal to the circuit board of the controller. Secure the rear cover to the motor housing by laser welding or ultrasonic welding at the riveting stop. The power connector is sealed and fixed to the rear end cover using laser welding or ultrasonic welding at the location of the welding sealing port; the six through holes on the top plane of the water-proof support sleeve are aligned with the six screw through holes on the front end face of the motor housing; similarly, the six threaded holes on the pump housing are also aligned with the six screw through holes on the front end face of the motor housing, and the pump housing, the water-proof support sleeve, and the motor housing are connected and fixed by six screws; the mechanical assembly of the pump body sub-component, the motor body sub-component, and the controller is completed.

[0018] The assembled embedded electronic water pump is installed into the two stepped circular cavities pre-set in the thermal management integrated module. The sealing rings three and four, along with these two stepped circular cavities, form mutually separated coolant flow paths. The sealing ring three, together with one of the stepped circular cavities pre-set in the thermal management integrated module, forms the inlet channel; the sealing ring four, together with the other stepped circular cavity pre-set in the thermal management integrated module, forms the outlet channel. The fastening nut is rotated to press the embedded electronic water pump against the end face of the pre-set circular cavity in the thermal management integrated module. Then, the fastening nut and the motor housing are connected and fixed inside the thermal management integrated module using three screws. This invention significantly reduces the complexity of the assembly process and substantially improves the finished product assembly qualification rate.

[0019] In summary, this utility model has the following beneficial effects:

[0020] 1. The innovative design integrates the impeller and the motor rotor assembly into a single assembly structure, eliminating the failure of the rotating parts of the embedded electronic water pump caused by continuous impact and corrosion of the coolant. It features extremely low fluid friction resistance and high-efficiency rotor dynamic balancing performance.

[0021] 2. The novel structural feature of the pump housing of this utility model is that, by optimizing the fluid flow channel resistance design of the pump housing, the coolant is mostly in a laminar flow state during the flow along the inner wall of the pump housing pipe, thereby reducing pressure loss and realizing continuous and stable operation of the embedded electronic water pump with large flow rate, high head, and low noise.

[0022] 3. The embedded electronic water pump and thermal management integrated module described in this utility model are highly integrated, reducing the number of coolant circuit pipes, water valves and actuators used in the thermal management system, saving layout space and reducing costs;

[0023] 4. The bearing 1 and the bearing 2 are made of semi-ceramic deep groove ball bearings without dust rings or engineering plastic deep groove ball bearings without dust rings. Because they have high speed, low noise, light weight, wear resistance, corrosion resistance, and especially self-lubricating properties, they are particularly suitable for long-term operation immersed in coolant.

[0024] 5. This utility model completely separates the pump body components and the motor body components through the water-proof support sleeve, avoiding the failure of the coil winding and the controller due to coolant leakage;

[0025] 6. The present invention provides a technical solution for assembling and fixing the stator core and its components inside the motor housing cavity by using three stator core fixing screws. Compared with the heat-fitting method for the stator core, the technical solution of the present invention is particularly easy to adjust and disassemble, greatly reducing the complexity of assembly and significantly improving the finished product assembly qualification rate.

[0026] 7. The stator core and the motor housing are coated with insulating and thermally conductive adhesive, which is beneficial to improving the heat dissipation and vibration resistance of the stator core and its components, reducing the iron loss of the stator core and the copper loss of the coil winding, and improving the output power of the motor.

[0027] 8. The wave-shaped spring pad described in this utility model is used to compensate for the dimensional tolerances accumulated during the assembly of related parts, and to limit the axial displacement of the motor rotor assembly, thus solving the problem of axial movement of the rotating shaft of the embedded electronic water pump.

[0028] 9. This utility model has a compact structure, good sealing performance, and high integration. It applies a speed closed-loop drive control strategy and is particularly suitable for electric vehicle thermal management integrated modules with higher requirements for modularity, lightweighting, and integration. Attached Figure Description

[0029] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments of the present invention and, together with their description, serve to explain the principles of the present invention.

[0030] Figure 1 This is an exploded view of the three-dimensional assembly structure of this utility model;

[0031] Figure 2 This is a schematic diagram of the overall assembly cross-sectional structure of this utility model;

[0032] Figure 3 This is a schematic diagram of the stator core assembly according to the present invention;

[0033] Figure 4 This is a schematic cross-sectional view of the assembly of the impeller and the motor rotor assembly of this utility model;

[0034] Figure 5 This is a schematic diagram of the waterproof support sleeve structure described in this utility model;

[0035] Figure 6 This is a schematic diagram of the pump base structure described in this utility model;

[0036] Figure 7 This is a schematic diagram of the impeller structure described in this utility model;

[0037] Figure 8 This is a schematic diagram of the pump housing structure described in this utility model;

[0038] Figure 9 This is a schematic diagram of the assembly of the motor housing, the rear end cover, and the fastening screw ring of this utility model.

[0039] In the attached diagram: 2. Impeller insert; 3. Screw through hole one; 5. Tooth profile fillet; 6. Screw three; 7. Riveted stop; 8. Auxiliary groove; 10. Rear end cover; 11. Welded sealing port; 12. Stator core fixing screw; 20. Sealing ring one; 21. Bearing one; 22. Bearing two; 23. Snap ring; 30. Fastening threaded ring; 31. Busbar terminal block; 32. Controller; 33. Power connector; 40. Motor housing; 41. Motor housing gasket; 42. Insulating end piece; 43. Coil winding; 45. Stator core; 50. Waterproof support sleeve; 51. Sealing ring two; 52. Threaded hole one; 53. Threaded hole two; 55. 56. Cylindrical boss; 57. Trapezoidal reinforcing rib; 58. Rectangular reinforcing rib; 60. Pump base; 61. Countersunk hole one; 65. Motor rotor assembly; 66. Injection molded part; 67. Rotor magnetic ring; 68. Locking screw; 70. Impeller; 71. Pump shaft; 72. Waveform spring washer; 75. Impeller blade bottom draft angle; 76. Impeller blade misalignment angle; 77. Impeller blade tooth pitch angle; 78. Impeller blade length; 79. Impeller blade helix angle; 80. Pump housing; 81. Sealing ring three; 82. Sealing ring four; 83. Guide sleeve; 85. Sealing ring five; 86. Inlet channel; 87. Outlet channel; 88. Fluid flow direction; 89. Threaded hole six. Detailed Implementation

[0040] The present invention will be further described below with reference to the accompanying drawings. It should be noted that, unless otherwise specifically stated, the relative arrangement and numerical values ​​of the components and steps described in these embodiments do not limit the scope of the present invention.

[0041] The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the invention or its application or use. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0042] The terms “comprising,” “having,” “alongside,” “configured as,” “set as,” “as provided,” “referring to,” and any variations thereof in the specification, claims, and accompanying drawings of this application are intended to cover a non-exclusive inclusion. For example, a process, method, system, product, or apparatus that includes a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such process, method, product, or apparatus. Additionally, the term “(degree)” indicates that its value is in units of angles.

[0043] In the description of this utility model, it should be understood that the terms "center," "length," "width," "height," "upper," "side," "axial," "backward," "circumference," "top," "bottom," "inner," and "outer," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model; unless otherwise expressly specified and limited; in addition, the terms "installation," "assembly," "connection," "fixing," "pairing," and "alignment," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal connection of two components. For those skilled in the art, the specific meaning of the above terms in this utility model can be understood according to the specific circumstances.

[0044] This utility model discloses an embedded electronic water pump for an integrated module of thermal management in electric vehicles, comprising: an impeller insert 2, a screw through hole 3, a tooth profile fillet 5, a screw 6, a riveted stop 7, an auxiliary groove 8, a rear end cover 10, a welded sealing port 11, a stator core fixing screw 12, a sealing ring 20, a bearing 21, a bearing 22, a retaining ring 23, a fastening screw ring 30, a busbar terminal block 31, a controller 32, a power connector 33, a motor housing 40, a motor housing sealing gasket 41, an insulating end piece 42, a coil winding 43, a stator core 45, a water-proof support sleeve 50, a sealing ring 51, and a screw... 52. Hole 1, 53. Threaded Hole 2, 55. Cylindrical Boss, 56. Trapezoidal Reinforcing Rib, 57. Rectangular Reinforcing Rib, 60. Pump Base, 61. Countersunk Hole 1, 65. Motor Rotor Assembly, 66. Injection Molded Part, 67. Rotor Magnetic Ring, 68. Locking Screw, 70. Impeller, 71. Pump Shaft, 72. Waveform Spring Washer, 75. Impeller Blade Bottom Draft Angle, 76. Impeller Blade Misalignment Angle, 77. Impeller Blade Tooth Pitch Angle, 78. Impeller Blade Length, 79. Impeller Blade Helix Angle, 80. Pump Housing, 81. Sealing Ring 3, 82. Sealing Ring 4, 83. Guide Sleeve, 85. Sealing Ring 5, 86. Inlet Channel, 87. Outlet Channel, 88. Fluid Flow Direction, 89. Threaded Hole 6.

[0045] The motor rotor assembly 65 shown in the attached drawings of this utility model includes a bearing 22, an injection molded part 66, a rotor magnetic ring 67, a locking screw 68, a pump shaft 71, and a wave spring washer 72. The cylindrical surface of the large end of the pump shaft 71 is provided with a spline for interference fit with the impeller insert 2. The top plane of the injection molded part 66 is provided with two threaded holes corresponding to the locking screw 68. The pump base 60 is provided with a countersunk hole 61 and an inlet channel 86. The bottom of the pump base 60 is provided with an inner circular cavity for fitting with the water-proof support sleeve 50. The rotor magnetic ring 67 is configured with two pole pairs.

[0046] The impeller 70 shown in the attached drawings of this utility model includes an impeller insert 2, a screw through hole 3, a tooth profile fillet 5, an impeller blade bottom draft angle 75, an impeller blade misalignment angle 76, an impeller blade tooth pitch angle 77, an impeller blade length 78, and an impeller blade helix angle 79. The total number of blades on one side of the impeller 70 is set to a range of 6 to 46, and the number of blades on both sides of the impeller 70 is set to be equal. The impeller blade tooth pitch angle 77 is set to be evenly distributed along the circumference of the impeller 70, and the impeller blade misalignment angle 76 is set to the relative angle between the blades on both sides of the impeller 70. The displacement angle value ranges from 1.0° to 5.0°; the length value of the impeller blade 78 is set to 0.40 to 0.60 times the radius value of the impeller 70; the helix angle value of the impeller blade helix angle 79 is set to 1.0° to 10.0°; the draft angle 75 at the bottom of the impeller blade is set to an arc shape; the tooth profile fillet 5 on the outer circumference of the impeller 70 refers to the fillet of one edge of the blade facing away from the fluid flow direction 88; the inner cavity of the impeller insert 2 is provided with a spline for assembly error prevention.

[0047] The water-proof support sleeve 50 shown in the attached drawings of this utility model is provided with a threaded hole 52, a threaded hole 53, a cylindrical boss 55, a trapezoidal reinforcing rib 56, and a rectangular reinforcing rib 57; a circular boss is provided at the center of the end face of the water-proof support sleeve 50, and the pump seat 60 is assembled on the circular boss provided at the center of the end face of the water-proof support sleeve 50. The bottom of the inner cavity of the water-proof support sleeve 50 is provided with a bearing chamber that is slidably assembled with the bearing 22. Two small threaded holes 53 are provided on the end face of the outer cylinder at the bottom of the water-proof support sleeve 50.

[0048] The pump housing 80 shown in the attached drawings of this utility model has an inlet channel 86, an outlet channel 87, a fluid flow direction 88, and a threaded hole 89. The bearing chamber in the internal circular cavity of the pump housing 80 is equipped with a bearing 21 and a retaining ring 23. The outer cylindrical surface of the pump housing 80 has two rectangular sealing grooves, and the two rectangular sealing grooves are respectively equipped with a sealing ring 81 and a sealing ring 82. At the same time, the large end face of the pump housing 80 has an end face annular groove, and a sealing ring 51 is installed inside the end face annular groove. The guide sleeve 83 is fitted into the circular cavity of the large end face of the pump housing 80 and is flush with the large end face of the pump housing 80. The end face of the guide sleeve 83 has a rectangular sealing ring groove, and a sealing ring 85 is installed inside the rectangular sealing ring groove.

[0049] The stator core 45 shown in the attached drawings of this utility model has three evenly distributed screw through holes on its outer circumference. The stator core 45 has six tooth slots, and each tooth crown of the stator core 45 has two auxiliary slots 8, which are rectangular. The motor housing 40 has three evenly distributed threaded holes inside its circular cavity, which are matched and positioned with the three evenly distributed screw through holes on the stator core 45. The front end face of the motor housing 40 has a sealing groove, inside which a motor housing sealing gasket 41 is installed. The front end face of the motor housing 40 also has six evenly distributed through holes. The rear end face of the motor housing 40 has three bosses that fit into the rear end cover 10. The outer circumference of the motor housing 40 has three evenly distributed threaded holes. The three oblong holes on the fastening ring 30 are matched with the three oblong holes on the end face of the fastening ring 30. The outer circumference of the fastening ring 30 is threaded. The inner ring of the fastening ring 30 is nested on the steps of the three bosses on the outer circumference of the motor housing 40. The outer circumference of the step of the rear end cover 10 is provided with an annular sealing groove, and a sealing ring 20 is installed in the annular sealing groove. The rear end cover 10 is also provided with a groove that fits into the three bosses on the rear end face of the motor housing 40. The coil winding 43 adopts a fractional slot concentrated winding design. The insulating end piece 42 is wound with single-layer copper enameled wire. The coil of the coil winding 43 is connected in a Δ (delta) connection. The controller 32 is provided with a power connector 33.

[0050] The bearings 21 and 22 shown in the attached drawings of this utility model are configured as semi-ceramic deep groove ball bearings without dust seals or engineering plastic deep groove ball bearings without dust seals.

[0051] Furthermore, the small end of the pump shaft 71 is fitted with bearing 22 by interference fit. The rotor magnetic ring 67 and the pump shaft 71 are injection molded and fixed by injection molding through injection molding part 66. The pump base 60 is connected and fixed to the water-proof support sleeve 50 by three screws through the countersunk hole 61 provided in the pump base 60 and the threaded hole 52 provided in the water-proof support sleeve 50. Then, bearing 21 and retaining ring 23 are assembled in the bearing chamber provided in the internal cavity of the pump housing 80.

[0052] Furthermore, the motor rotor assembly 65 and bearing 22 are slidably fitted into the cavity of the water-proof support sleeve 50 and the bearing chamber at the bottom. The rectangular reinforcing rib 57 and the auxiliary groove 8 are assembled accordingly. The pump base 60 is connected and fixed to the water-proof support sleeve 50 using three screws through the countersunk hole 61 of the pump base 60 and the threaded hole 52 of the water-proof support sleeve 50. The inner cavity of the impeller insert 2 is press-fitted onto the splined shaft at the large end of the pump shaft 71. One end face of insert 2 is fitted with the top plane of injection molded part 66. Impeller 70 is connected and fixed to motor rotor assembly 65 by two locking screws 68. Wave spring washer 72 is then fitted onto the bearing position at the large end of pump shaft 71. Pump housing 80 and related components mounted on it are slidably fitted into the end face of water-proof support sleeve 50, so that the inner ring of bearing 21 is slidably connected to the bearing part at the large end of pump shaft 71. The mechanical assembly of pump body sub-components is completed.

[0053] Furthermore, an insulating end piece 42 is installed on each of the two end faces of the stator core 45. A coil winding 43 is wound on the insulating end piece 42. The busbar terminal 31 is connected and fixed to the coil winding 43. Then, the stator core 45 and its related components are pre-positioned by aligning and engaging with the three evenly distributed screw through holes on the stator core 45 and the three evenly distributed threaded holes inside the circular cavity of the motor housing 40. The stator core 45 and its related components are then assembled into the circular cavity of the motor housing 40. Three stator core fixing screws 12 are then used to connect and fix the stator core 45 and its related components to the motor housing 40. Insulating thermally conductive adhesive is applied to the assembly joint surface between the stator core 45 and the motor housing 40. The mechanical assembly of the motor body components is completed.

[0054] Furthermore, the waterproof support sleeve 50 and its assemblies are assembled with the motor body components. The inner cylindrical surface of the bottom of the waterproof support sleeve 50 is transitionally assembled with the outer cylindrical surface of the bearing chamber at the bottom of the motor housing 40. The waterproof support sleeve 50 is tightened and fixed to the motor housing 40 using two screws through the two threaded holes 53. The controller 32 is connected and fixed to the rear cavity of the motor housing 40 with screws. The three-phase power lead on the busbar terminal 31 is welded and fixed to the circuit board of the controller 32. The rear cover 10 is snapped and fixed to the motor housing 40 by laser welding or ultrasonic welding at the position of the riveting stop 7. By welding the sealing port 11, the power connector 33 and the rear cover 10 are sealed and fixed using laser welding or ultrasonic welding; the six through holes on the top plane of the water-proof support sleeve 50 are aligned with the six screw through holes on the front face of the motor housing 40; similarly, the six threaded holes 89 on the pump housing 80 are also aligned with the six screw through holes on the front face of the motor housing 40, and the pump housing 80, the water-proof support sleeve 50, and the motor housing 40 are connected and fixed by six screws; the assembly of the pump body sub-component, the motor body sub-component, and the controller mechanism is completed;

[0055] Furthermore, the assembled embedded electronic water pump is installed into the two stepped circular cavities pre-set in the thermal management integrated module. The sealing rings 81 and 82, together with the two stepped circular cavities, form a coolant flow path 88 that is separated from each other. The sealing ring 81 and one of the stepped circular cavities pre-set in the thermal management integrated module form an inlet channel 86, and the sealing ring 82 and the other stepped circular cavity pre-set in the thermal management integrated module form an outlet channel 87. The fastening ring 30 is rotated to press the embedded electronic water pump against the end face of the circular cavity pre-set in the thermal management integrated module, and then the fastening ring 30 and the motor housing 40 are connected and fixed inside the thermal management integrated module by three screws 36.

[0056] In addition to the above description, although some specific embodiments of the present invention have been described in detail by way of examples, those skilled in the art should understand that the above examples are only for illustration and not for limiting the scope of the present invention; modifications can be made to the above embodiments without departing from the scope and spirit of the present invention, and any technical solutions formed by equivalent substitution or equivalent transformation shall fall within the protection scope of the present invention, the scope of which is defined by the appended claims.

Claims

1. An embedded electronic water pump for an integrated thermal management module in an electric vehicle, characterized in that, include: Impeller insert, screw through hole 1, tooth profile fillet, screw 3, riveting stop, auxiliary groove, rear end cover, welded sealing port, stator core fixing screw, sealing ring 1, bearing 1, bearing 2, retaining ring, fastening screw ring, manifold terminal block, controller, power connector, motor housing, motor housing gasket, insulating end piece, coil winding, stator core, water-proof support sleeve, sealing ring 2, threaded hole 1, threaded hole 2, cylindrical boss, trapezoidal reinforcing rib, rectangular reinforcing rib, pump base, countersunk hole 1, motor rotor assembly, injection molded part, rotor magnetic ring, locking screw, impeller, pump shaft, wave spring washer, impeller blade bottom draft angle, impeller blade misalignment angle, impeller blade tooth pitch angle, impeller blade length, impeller blade helix angle, pump housing, sealing ring 3, sealing ring 4, guide sleeve, sealing ring 5, inlet channel, outlet channel, fluid flow direction, threaded hole 6; The motor rotor assembly includes the second bearing, the injection molded part, the rotor magnetic ring, the locking screw, the pump shaft, and the wave spring washer; the cylindrical surface of the large end of the pump shaft is provided with a spline for interference fit with the impeller insert, and the top plane of the injection molded part is provided with two threaded holes corresponding to the locking screw; the pump base is provided with the first countersunk hole and the inlet channel, and the bottom of the pump base is provided with an inner circular cavity for fit fit with the water-proof support sleeve; the impeller is provided with the impeller insert, the first screw through hole, the tooth profile fillet, the impeller blade bottom draft angle, the impeller blade misalignment angle, the impeller blade tooth pitch angle, the impeller blade length, and the impeller blade helix angle; The water-proof support sleeve is provided with threaded hole one, threaded hole two, cylindrical boss, trapezoidal reinforcing rib, and rectangular reinforcing rib; a circular boss is provided at the center of the end face of the water-proof support sleeve; a bearing chamber for sliding assembly with bearing two is provided at the bottom of the inner cavity of the water-proof support sleeve; two small threaded holes two are provided on the end face of the outer cylinder at the bottom of the water-proof support sleeve; the controller is provided with the power connector; the pump housing is provided with the inlet channel, the outlet channel, the fluid flow direction, and threaded hole six; the bearing chamber in the inner cavity of the pump housing assembles bearing one, bearing two... The stator core has three evenly distributed screw through holes on its outer circumference. Each tooth crown of the stator core has two auxiliary slots, which are rectangular. The mating surfaces of the stator core and the motor housing are coated with insulating and thermally conductive adhesive. The three-phase power leads on the busbar terminals are welded and fixed to the circuit board of the controller. The rear end cover is snapped and fixed to the motor housing using laser welding or ultrasonic welding at the riveting stop position. The power connector is sealed and fixed to the rear end cover using laser welding or ultrasonic welding at the welding sealing port position.

2. An embedded electronic water pump for an integrated thermal management module of an electric vehicle according to claim 1, characterized in that, The total number of blades on one side of the impeller is set to 6 to 46, and the number of blades on both sides of the impeller is set to be equal. The tooth pitch angle of the impeller blades is set to be evenly distributed along the circumference of the impeller. The blade misalignment angle is set to be the angle between the relative angular displacement of the blades on both sides of the impeller, ranging from 1.0° to 5.0°. The length of the impeller blades is set to be 0.40 to 0.60 times the radius of the impeller. The helix angle of the impeller blades is set to be 1.0° to 10.0°. The draft angle of the bottom of the impeller blades is set to be arc-shaped. The tooth profile fillet on the outer circumference of the impeller refers to the rounded corner of one edge of the blade facing away from the fluid flow direction. The inner cavity of the impeller insert is provided with splines for assembly error prevention.

3. An embedded electronic water pump for an integrated thermal management module for electric vehicles according to claim 1, characterized in that, The outer cylindrical surface of the pump housing has two rectangular sealing grooves, and the two rectangular sealing grooves are respectively equipped with sealing ring three and sealing ring four. At the same time, the large end face of the pump housing has an end face annular groove, and sealing ring two is installed inside this end face annular groove. The flow guide sleeve is fitted into the circular cavity of the large end face of the pump housing and is flush with the large end face of the pump housing. The end face of the flow guide sleeve has a rectangular sealing annular groove, and sealing ring five is installed inside this rectangular sealing annular groove.

4. An embedded electronic water pump for an integrated thermal management module of an electric vehicle according to claim 1, characterized in that, The bearing 1 and the bearing 2 are configured as either semi-ceramic deep groove ball bearings without dust seals or engineering plastic deep groove ball bearings without dust seals.

5. An embedded electronic water pump for an integrated thermal management module of an electric vehicle according to claim 1, characterized in that, The rotor magnetic ring has 2 pole pairs, and the stator core has 6 slots.

6. An embedded electronic water pump for an integrated thermal management module for electric vehicles according to claim 1, characterized in that, The depth of the auxiliary groove is set to be between 0.36 mm and 1.20 mm, and the width of the auxiliary groove is set to be equal to the width of the slot opening of the stator core.

7. An embedded electronic water pump for an integrated thermal management module of an electric vehicle according to claim 1, characterized in that, The motor housing has three evenly distributed threaded holes inside its circular cavity, which are matched and positioned with the three evenly distributed screw through holes on the stator core. A sealing groove is provided on the front end face of the motor housing, inside which a sealing gasket is installed. The front end face of the motor housing also has six evenly distributed through holes. The rear end face of the motor housing has three bosses that fit into the rear end cover. The outer circumference of the motor housing has three evenly distributed threaded holes that match the three oblong holes on the fastening ring. The end face of the fastening ring has three evenly distributed oblong holes. The outer circumference of the fastening ring has a full thread. The inner ring of the fastening ring is nested on the steps of the three bosses on the outer circumference of the motor housing. The outer circumference of the steps on the rear end cover has an annular sealing groove, inside which the sealing ring is installed. The rear end cover also has grooves that fit into the three bosses on the rear end face of the motor housing.

8. An embedded electronic water pump for an integrated thermal management module of an electric vehicle according to claim 1, characterized in that, The coil winding adopts a fractional slot concentrated winding design, and the insulating end plates are wound with single-layer copper enameled wire. The coil windings are connected using a Δ connection method. The busbar terminals are connected and fixed to the coil windings.

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