A brushless fuel pump

Abstract

The utility model discloses a brushless fuel pump, including motor assembly and the controller assembly of setting in the lower extreme of motor assembly, the motor assembly includes the motor casing, motor stator subassembly, oil separation sleeve subassembly and motor rotor subassembly that set gradually from outside to inside, the controller assembly includes the controller of setting in the lower extreme of motor casing, and is provided with the insulating plate between controller and motor casing, be provided with the back cover for including controller on the motor casing, be provided with the wire hole that motor stator subassembly wire passes through on the motor casing, be provided with the junction box that wire and power cord access and controller are connected on the back cover. Adopt control assembly to replace the carbon brush and commutator in the prior art, not only can guarantee motor assembly rotating speed, torque and the stability of operation, make it satisfy the on-demand fuel supply of automobile fuel pump, also will not appear friction, thereby guarantee the service life of fuel pump.

Description

Technical Field

[0001] This utility model belongs to the technical field of automotive fuel supply systems, specifically relating to a brushless fuel pump. Background Technology

[0002] In the prior art, fuel pumps typically use a brushed DC motor driven by a 12V power supply. Its typical structure includes a motor part and a pump body part. The motor part consists of a stator (permanent magnet and carbon brush), a rotor (commutator and armature winding), and a power supply. The current direction is switched by the carbon brush contacting the commutator. The pump body part is assembled with an impeller, an inlet end cover, and an outlet end cover to form a pump chamber. Then, the motor shaft drives the impeller to rotate to achieve the output of fuel medium pressure.

[0003] Because of the use of carbon brushes and commutators, wear and noise will occur during operation, which will affect the service life of the fuel pump. Especially when using special fuels (such as methanol and ethanol), the wear of carbon brushes and commutators will be accelerated, further affecting the service life of the fuel pump. Utility Model Content

[0004] This invention proposes a brushless fuel pump that can not only meet the high fuel pressure and large flow requirements of large heavy trucks, but also ensure the service life of the fuel pump.

[0005] Therefore, the technical solution adopted by this utility model is as follows: a brushless fuel pump, including a motor assembly and a controller assembly disposed at the lower end of the motor assembly. The motor assembly includes a motor housing, a motor stator assembly, an oil separator assembly, and a motor rotor assembly arranged sequentially from the outside to the inside. The controller assembly includes a controller disposed at the lower end of the motor housing, and an insulating plate is disposed between the controller and the motor housing. The motor housing is provided with a rear cover for including the controller. The motor housing is provided with a wire passage hole for the power supply stator assembly wires to pass through. The rear cover is provided with a junction box for the wires and power lines to be connected to the controller.

[0006] As a preferred embodiment of the above scheme, the rear end of the motor housing is provided with a mounting groove for mounting the controller, the mounting groove is filled with thermally conductive fixing adhesive, the rear cover is provided with a heat dissipation structure, and both the motor housing and the rear cover are made of aluminum alloy.

[0007] A further preferred embodiment is that an oil separator sleeve is provided between the motor rotor assembly and the motor stator assembly.

[0008] In a further preferred embodiment, the motor stator assembly includes a stator core, and stator assemblies with windings are provided at both the upper and lower ends of the stator core.

[0009] More preferably, the motor rotor assembly includes a motor shaft and a rotor assembly disposed outside the motor shaft.

[0010] The beneficial effects of this utility model are as follows: By replacing the carbon brushes and commutator in the prior art with control components, the speed, torque and smooth operation of the motor assembly can be guaranteed, so as to meet the fuel pump's on-demand fuel supply. At the same time, friction will not occur. Furthermore, by isolating the motor rotor assembly and the motor stator assembly in the motor assembly through the oil separator sleeve assembly and the connecting plate assembly, corrosion of the motor stator assembly in special oils can be effectively prevented, thereby ensuring the service life of the fuel pump. Attached Figure Description

[0011] Figure 1 This is a schematic diagram of the present invention (the arrows in the diagram indicate the direction of medium flow).

[0012] Reference numerals in the attached diagram: Motor housing-1, Pump head-2, Oil inlet-3, Oil outlet-4, Cycloidal gear-5, Gear sleeve-6, Gear retaining sleeve-7, Upper gear cover plate-8, Lower gear cover plate-9, Motor shaft-10, Oil separator sleeve-11, Lower bearing-12, Connecting disc-13, Upper bearing-14, Safety valve-15, Oil drain nozzle-16, Controller-17, Insulation board-18, Rear cover-19, Junction box-20, Thermally conductive fixing adhesive-21, Stator assembly-22, Stator core-23, Rotor assembly-25. Detailed Implementation

[0013] The present invention will be further described below with reference to embodiments and accompanying drawings: like Figure 1 As shown, a brushless fuel pump mainly consists of a motor assembly and a control assembly. The motor assembly includes, from the outside to the inside, a motor housing 1, a motor stator assembly, an oil separator assembly, and a motor rotor assembly. The controller assembly is located at the lower end of the motor assembly and is used to control the operation of the motor assembly.

[0014] The controller assembly includes a controller 17 disposed at the lower end of the motor housing 1, with an insulating plate 18 between the controller 17 and the motor housing 1. A rear cover 19 is provided on the motor housing 1 for housing the controller 17. A wire-passing hole is provided on the motor housing 1 for the stator assembly wires to pass through. A junction box 20 for wires and power lines to connect to the controller is provided on the rear cover 19. The controller employs existing technology with functions such as information reception, information processing, and information transmission.

[0015] To facilitate controller heat dissipation, a mounting groove for installing the controller is provided at the rear end of the motor housing 1. Thermally conductive adhesive 21 is injected into the mounting groove. This adhesive not only transfers heat but also secures the wires or power cords located within the mounting groove. A heat dissipation structure is also provided on the rear cover 19, and both the motor housing 1 and the rear cover 19 are made of aluminum alloy. The controller's heat is transferred to the motor housing or rear cover via the thermally conductive adhesive. Since the fuel pump is installed outside the fuel tank, natural wind can dissipate heat from the motor housing and rear cover, thus ensuring the controller's heat dissipation.

[0016] To facilitate the entry and exit of the medium, a pump head assembly is provided on the upper end of the motor assembly. The pump head assembly includes a pump head 2 mounted on the motor housing 1. Inside the pump head 2, there is an oil inlet channel with one end connected to the left side of the pump head 2 and an oil outlet channel with one end connected to the right side of the pump head 2. A cycloidal gear assembly is provided at the lower end of the pump head 2, and the other end of the oil inlet channel and the other end of the oil outlet channel are connected through the cycloidal gear assembly. An oil inlet nozzle 3 connected to the output pipe of the oil tank is provided at the end of the oil inlet channel, and an oil outlet nozzle 4 connected to the oil inlet pipe of the powertrain is provided at the end of the oil outlet channel.

[0017] An oil separator sleeve 11 is provided between the motor rotor assembly and the motor stator assembly, and a connecting plate 13 is provided between the pump head 2 and the motor assembly. To support the motor shaft, a lower bearing 12 for supporting the lower end of the motor shaft is embedded within the oil separator sleeve, and an upper bearing 14 for supporting the upper end of the motor shaft is embedded within the lower end of the connecting plate. The upper end of the connecting plate 13 has a mounting end face located between the pump head 2 and the motor housing 1. Through the cooperation of the oil separator sleeve and the connecting plate, the dry and wet separation of the motor rotor assembly and the motor stator assembly can be effectively achieved, thereby preventing the motor stator assembly from being wetted and corroded by the medium, and thus ensuring the service life of the fuel pump.

[0018] The cycloidal gear assembly includes a cycloidal gear 5 sleeved on the upper end of the motor shaft. The cycloidal gear 5 is embedded in a gear retaining sleeve 7 via a gear sleeve 6. An upper gear cover plate 8 and a lower gear cover plate 9 are respectively provided at the upper and lower ends of the gear retaining sleeve 7 for sealing the cycloidal gear 5. Simultaneously, a connecting hole is provided on the upper gear cover plate 8 at the positions corresponding to the oil inlet and oil outlet channels. When the motor shaft rotates, it drives the cycloidal gear to work, thereby allowing the medium to flow from the oil inlet nozzle, through the oil inlet channel, the cycloidal gear assembly, and the oil outlet channel, and then out of the oil outlet nozzle.

[0019] To prevent pipe rupture in case of blockage in the oil outlet or oil pipeline, an oil drain hole connected to the oil outlet channel is provided inside the pump head 2, and a safety valve 15 is provided on the oil drain hole. An oil drain nozzle 16 connected to the return oil pipeline on the power assembly is provided on the pump head 2 corresponding to the oil drain hole. When the pressure of the medium in the oil outlet channel is greater than the set value, the safety valve will open, so that the medium returns to the return oil pipeline from the oil drain hole through the oil drain nozzle.

[0020] During the assembly of the entire fuel pump, it is first assembled into several large components, and then the whole unit is assembled. Specifically: The safety valve, drain nozzle, inlet nozzle, and outlet nozzle are installed on the pump head to form a non-powered pump head assembly. The cycloidal gear assembly is assembled. The motor stator assembly is installed in the motor housing to form a motor housing assembly. The upper bearing is pressed onto the connecting plate to form a connecting plate assembly. The lower bearing is pressed onto the oil separator sleeve to form an oil separator sleeve assembly. Then, the oil separator sleeve assembly is installed on the motor housing assembly, the motor rotor assembly is placed inside the oil separator sleeve assembly, and the lower end of the motor shaft is supported by the lower bearing. The connecting plate is then placed on the upper end of the motor shaft, and the upper end of the motor shaft is supported by the upper bearing. The cycloidal gear assembly is then installed on the upper end of the motor shaft, so that when the motor shaft rotates, the inner rotor in the cycloidal gear can rotate. Finally, the non-powered pump head assembly, the connecting plate assembly, and the motor housing assembly are fixed, thus completing the installation of the upper end of the motor. Fix the controller to the lower end of the motor housing, with an insulating plate between the controller and the motor housing. Then fix the stator wiring to the controller. Next, fill the mounting groove with thermally conductive fixing adhesive. Then fix the controller's power cord and wires to the junction box, the junction box to the rear cover, and the rear cover to the motor housing. This completes the installation of the entire fuel pump.

Claims

1. A brushless fuel pump, characterized in that: The device includes a motor assembly and a controller assembly located at the lower end of the motor assembly. The motor assembly includes a motor housing (1), a motor stator assembly, an oil separator assembly, and a motor rotor assembly arranged sequentially from the outside to the inside. The controller assembly includes a controller (17) located at the lower end of the motor housing (1), and an insulating plate (18) is provided between the controller (17) and the motor housing (1). The motor housing (1) is provided with a rear cover (19) for including the controller (17). The motor housing (1) is provided with a wire hole through which the power supply stator assembly wires pass. The rear cover (19) is provided with a junction box (20) for wires and power lines to be connected to the controller.

2. The brushless fuel pump according to claim 1, characterized in that: The rear end of the motor housing (1) is provided with a mounting groove for mounting the controller. The mounting groove is filled with thermally conductive fixing adhesive (21). The rear cover (19) is provided with a heat dissipation structure. Both the motor housing (1) and the rear cover (19) are made of aluminum alloy.

3. The brushless fuel pump according to claim 1, characterized in that: An oil separator sleeve (11) is provided between the motor rotor assembly and the motor stator assembly.

4. The brushless fuel pump according to claim 1, characterized in that: The motor stator assembly includes a stator core (23), and stator assemblies (22) with windings are provided at both the upper and lower ends of the stator core (23).

5. The brushless fuel pump according to claim 1, characterized in that: The motor rotor assembly includes a motor shaft (10) and a rotor assembly (25) disposed outside the motor shaft (10).

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