Pump assembly

Abstract

The invention is a pump assembly (1) for a cooling system of an operating assembly of a vehicle, which extends with respect to an axis (X-X) and comprises: 1) a container group (2), which comprises a container body (21) and an auxiliary body (22) delimiting a dry chamber (201) and a wet chamber (202); ID an impeller group (3) housed in the wet chamber (202), comprising a blade body (30); ill) an electric motor group (4) comprising a stator (41), housed in the dry chamber (201), and a rotor (42), housed in the wet chamber (202); iv) a shaft group (5) mainly housed in the wet chamber (202), comprising: a shaft (50) extending along the axis (X-X) comprising a fixed end (500) engaged with the auxiliary body (22); two rolling elements (55', 55") axially spaced apart along the axis (X-X) engaged radially internally with the shaft (50) and radially externally by the rotor (42) and the impeller group (3), so that the rotor (42) and the impeller group (3) freely rotate with respect to the shaft (50).

Description

"PUMP ASSEMBLY"DESCRIPTION

[0001] The present invention relates to a pump assembly of a cooling system of a vehicle.

[0002] In this disclosure, the term "vehicle" relates to any means of locomotion, without any limitation related to type or size, i.e., a motor vehicle or a tractor trailer.

[0003] In other words, the present invention relates to the automotive field, and in detail to the thermal management system of an operating assembly of a vehicle.

[0004] In particular, in the present disclosure, "operating assembly" means a specific component or group of components for carrying out a given operation necessary for the motion of the vehicle. In a preferred embodiment, the "operating assembly" comprises the motor assembly, e.g., of endothermic type, electric type, or hybrid type.

[0005] In further constructional variants, the "operating assembly" comprises other vehicle components, either mechanical, such as a transmission assembly, or electrical, such as a "battery pack" or "electric motor", included in the vehicle.

[0006] In the prior art, multiple embodiments of pump assemblies for a cooling system of an operating assemblyof a vehicle are known, which are distinguished by the actuation types.

[0007] Specifically, the pump assembly of the present invention fits into such a context, being of the electrically actuated type. In other words, the pump assembly of the present invention comprises at least one electric motor which commands the rotary movement of the impeller group included therein, thus commanding the movement of the cooling liquid which flows in the cooling system to which the pump assembly is fluidically connectable .

[0008] In particular, the "cooling liquid" is a water- based liquid, e.g., a solution comprising water and glycol.

[0009] A multiplicity of technical solutions of pump assemblies comprising an electric drive with an electric motor are known, in which the rotor is "wet", i.e., is in the hydraulic part of the pump assembly so that it is cooled precisely by the cooling liquid moved by the impeller group.

[0010] A typical problem in such embodiments is related to the need to have an efficient rotation of the blade element included in the impeller group.

[0011] Therefore, it is the object of the present invention to provide a pump assembly for a cooling systemof an operating assembly of a vehicle which solves such a typical problem of the prior art.

[0012] Such an object is achieved by a pump assembly according to claim 1. Such an object is also achieved by a method of manufacturing a pump assembly according to claim 11. The claims dependent thereon relate to preferred constructional variants having further advantageous aspects.

[0013] The object of the present invention will now be described in detail, with the ais of the accompanying drawings, in which:

[0014] - figure 1 shows a section view of a pump assembly according to the present invention;

[0015] - figures 2a and 2b show section views of a shaft group and a rotor of a pump assembly in figure 1;

[0016] - figure 2b' shows a section view of the rotor in figure 2b;

[0017] - figure 3 shows a section view of the rotor mounted to the shaft group shown in figures 2a and 2b;

[0018] - figure 3' shows a section view of the rotor mounted to the shaft group in figure 3;

[0019] - figure 4 is a section view of the impeller group mounted, by co-molding, according to the present invention, to the rotor and shaft group in figure 3;

[0020] - figure 5a shows a section view of a shaftgroup of a pump assembly according to a constructional variant;

[0021] - figure 6 shows a section view of the rotor mounted to the shaft group in figure 6a;

[0022] - figure 7 is a section view of the impeller group mounted, by co-molding, according to the present invention, to the rotor and shaft group in figure 6.

[0023] In the aforesaid drawings, reference numeral 1 indicates as a whole a pump assembly for a cooling system of an operating assembly of a vehicle, e.g., of the internal combustion type.

[0024] The pump assembly 1 of the present invention extends mainly lengthwise with respect to axis X-X.

[0025] According to the invention, the pump assembly 1 comprises a container group 2.

[0026] Preferably, the container group 2 is suitable for containing at least the majority of the components of the pump assembly 1 of the present invention, described below.

[0027] Preferably, the container group 2 is fluidically connectable to the pipes of the cooling system, in which the cooling liquid, moved by the pump assembly 1, flows.

[0028] The container group 2 comprises a container body 21 and an auxiliary body 22.

[0029] The container group 2 delimits a dry chamber201 and a wet chamber 202 in the coupling between the container body 21 and the auxiliary body 22. In other words, the cooling liquid has free access into the wet chamber 202, while the cooling liquid is prevented from entering into the dry chamber 201, which is sealed off from said wet chamber 202.

[0030] The wet chamber 202 comprises a central portion 202' along the axis X-X and the dry chamber 201 comprises an annular portion 201', which surrounds said central portion 202'.

[0031] In other words, according to a preferred embodiment, the container body 21 and the auxiliary body 22 are mutually sealed. Preferably, appropriate gaskets are provided on the container body 21 or auxiliary body 22.

[0032] According to a preferred embodiment, the container group 2 is mountable with special components of the vehicle in which system fluid pipes are created, e.g., special systems in which operating assemblies and / or valve assemblies are housed. For example, said components comprise specific volute portions in which the pump assembly 1 operates.

[0033] According to a preferred embodiment, the container group 2 comprises a bottom wall.

[0034] Preferably, said bottom wall 220 is included in the auxiliary body 22.

[0035] Preferably, said bottom wall is included in the container body 21.

[0036] According to a preferred embodiment, the bottom wall 220 comprises a bottom disc made of metal material.

[0037] According to a preferred embodiment, the container body 21 is made of a metal material, e.g., of an aluminum alloy.

[0038] According to a preferred embodiment, the container body 21 is made of a plastic material, e.g., of PPS.

[0039] According to a preferred embodiment, the auxiliary body 22 is made of a plastic material, e.g., of PPS.

[0040] According to a preferred embodiment, the bottom wall 220 comprises a disc portion made of a metal material.

[0041] According to a further preferred embodiment, the container group 2 comprises a volute body fluidically connected to the pipes of the cooling system.

[0042] Preferably, the volute body is suitable for engaging the container body 21 and / or the auxiliary body 22. Preferably, the container group 2, in the coupling between the volute body and the container body 21 and / orthe auxiliary body 22, delimits an impeller portion 202" on the top of the wet chamber 202, in which the blade element 30 of the impeller group 3 (described below) is housed. Specifically, the wet chamber 202, in which the cooling liquid flows, is totally defined in the coupling between the volute body and the container body 21 and / or the auxiliary body 22.

[0043] According to a preferred embodiment, the volute body is made of a plastic material, e.g., of PPS material.

[0044] As mentioned, the pump assembly 1 comprises an impeller group 3 housed in the wet chamber 202, comprising a blade body 30.

[0045] According to a preferred embodiment, such as that shown in the accompanying figures, the pump assembly 1 further comprises a blade cover 300 mountable to the blade body 30 of the impeller group 3. As a function of the shape of the blade body 3, said blade cover 300 is in one piece, i.e. it is included in the impeller group 3, or is a distinct component engaged with the blade body 3.

[0046] Preferably, the impeller group 3 is made of a plastic material, preferably of PPS.

[0047] Furthermore, the pump assembly 1 comprises an electric motor 4 comprising a stator 41, housed in the first chamber 201, and a rotor 42, housed in the secondchamber 202.

[0048] Preferably, the rotor 42 is housed in the central portion 202', while the stator is housed in the annular portion 201'.

[0049] Preferably, the rotor 42 comprises rotor poles 421, e.g., specific magnetic elements.

[0050] Preferably, the rotor 42 comprises a rotor body 420.

[0051] Preferably, the rotor body 420 comprises a plurality of packed sheet elements.

[0052] According to a preferred embodiment, the sheet elements define in their packing appropriate housings in which the rotor poles 421 are placed.

[0053] According to the present invention, the pump assembly 1 comprises a shaft group 5 mainly housed in the wet chamber 202, comprising:- a shaft 50 extending along the axis X-X in the central portion 202' comprising a fixed end 500 engaged with the auxiliary body 22; two rolling elements 55', 55" engaged radially internally by the shaft 50 and radially externally by the rotor 42 and the impeller group 3, so that the rotor 42 and the impeller group 3 freely rotate with respect to the shaft 50.

[0054] According to a preferred embodiment, theaforesaid disc portion is made of a metal material. Preferably, the shaft 50 is also made of a metal material. Preferably, the shaft 50 and the disc portion are connected by force coupling.

[0055] According to a preferred embodiment, the shaft comprises a free end 501 opposite to the fixed end 500.

[0056] Preferably, the geometry of the shaft group 5 is such that the rolling elements 55', 55" are closer to the free end 501 than to the fixed end 500.

[0057] According to a preferred embodiment, the shaft group 5 comprises a hollow cylinder 51 extending along the axis X-X engaged internally by the two rolling elements 55', 55" and externally by the rotor 42 and the impeller group 3.

[0058] According to a preferred embodiment, the rotor 42 and the hollow cylinder 51 have substantially the same axial dimension along the axis X-X.

[0059] According to a preferred embodiment, the impeller group 3 comprises a control group 35, which extends lengthwise along the axis X-X from the blade body 30.

[0060] According to a preferred embodiment, the control group 35 extends radially and contains the rotor 42 therein.

[0061] Preferably, the control group 35 is engagedwith the hollow cylinder 51 and the rotor 42 by firmly connecting them.

[0062] According to a preferred embodiment, the hollow cylinder 51 has an outer surface 511 suitable for facilitating the engagement with the rotor 42.

[0063] Preferably, the hollow cylinder 51 has an inner surface 512 engaged with the two rolling elements 55', 55".

[0064] Preferably, the hollow cylinder 51 and the rotor 42 are coupled by force coupling.

[0065] According to a preferred embodiment, the impeller group 3 is co-molded on the hollow cylinder 51 containing the rotor 42.

[0066] According to a preferred embodiment, the rotor 42 is positioned on the shaft group 5 so as to engage the rolling elements 55', 55".

[0067] Preferably, the rotor 42 directly engages the rolling elements 55', 55", e.g., by being coupled thereto, preferably to their respective outer washer.

[0068] Preferably, the rotor 42 indirectly engages the rolling elements 55', 55", e.g., being through the hollow cylinder 51 which contains them.

[0069] According to a preferred embodiment, the rotor 42 is positioned on the shaft group 5, preferably on the hollow cylinder 51 or directly on the rolling elements55',55" so that, all together, they form a "complex component;" said "complex component" is placed in an appropriate mold in which the impeller group 3 is molded onto said "complex component".

[0070] According to a preferred embodiment, the rotor 42 is positioned on rolling elements 55', 55" and shaft 50 so that, all together, they form a "complex component"; said "complex component" is placed in an appropriate mold in which the impeller group 3 is molded onto said "complex component".

[0071] According to a further preferred embodiment, the rotor 42 is positioned on the hollow cylinder 51 so that, all together, they form a "complex component"; said "complex component" is placed in an appropriate mold in which the impeller group 3 is molded onto said "complex component". Afterward, said "complex component" is mounted together with the other components of the shaft group 5, such as the shaft 50 and the rolling elements 55', 55".

[0072] According to a preferred embodiment, the hollow cylinder 51 is sealingly closed at the axial ends by the two rolling elements 55', 55". Preferably, the rolling elements 55', 55" are lubricated and thus suitable for high rotations without experiencing problems of wear and tear.

[0073] According to a preferred embodiment, the shaft50 comprises internal retaining elements engaged by the two rolling elements 55', 55".

[0074] According to a preferred embodiment, said retaining element is an annular protrusion 505, of the shaft 50 itself, suitable for axially engaging the rolling elements 55', 55".

[0075] According to a preferred embodiment, said retaining element is an inner hollow cylinder 52 engaged by the shaft 50 and the two rolling elements 55', 55".

[0076] According to such a preferred embodiment, the inner hollow cylinder 52 is integrally fixed, e.g., by geometric coupling, with the shaft 50. In other words, the shaft 50 is rotationally fixed and the inner hollow cylinder 52 is also rotationally fixed in turn.

[0077] According to a preferred embodiment, the rolling element 55', 55" is a ball bearing;

[0078] According to a preferred embodiment, the housing element 55', 55" is a metal component.

[0079] According to a preferred embodiment, the rolling element 55', 55" is a tapered bearing.

[0080] As mentioned above, the present invention further relates to a method of manufacturing a pump assembly 1 having the aforesaid features.

[0081] Specifically, the present invention relates tothe method of manufacturing a pump assembly 1, where the step of co-molding the impeller group 3 onto the rotor 42 and the shaft group 5 is present.

[0082] According to a preferred embodiment, the present invention also relates to a step in which the rotor 42 is positioned on the shaft group 50 so that, all together, they form a "complex component"; said "complex component" is placed in an appropriate mold in which the impeller group 3 is molded onto said "complex component".

[0083] According to a preferred embodiment, the rotor 42 is mounted directly on the rolling elements 55', 55" and the shaft 50.

[0084] Preferably, the rotor 42 is positioned on the shaft 5 and the rolling elements 55', 55" so that, all together, they form a "complex component"; said "complex component" is placed in an appropriate mold in which the impeller group 3 is molded onto said "complex component". Preferably, mounting said "complex component" includes inserting a rolling element into the rotor, then inserting the shaft, then inserting the second rolling element into the rotor.

[0085] According to a preferred embodiment, the rotor 42 is mounted to the hollow cylinder 51. Preferably, the hollow cylinder 51 is engaged with the rolling elements 55', 55" and mounted to the shaft 50, before engaging itwith the rotor 42 and / or the impeller group 3.Preferably, the hollow cylinder 51 is engaged with the rolling elements 55', 55" mounted to the shaft 50, after engaging it with the rotor 42 and / or the impeller group 3.

[0086] According to a preferred embodiment, the present invention also relates to a step in which the rotor 42 is positioned on the hollow cylinder 51 so that, all together, they form a "complex component"; said "complex component" is placed in an appropriate mold in which the impeller group 3 is molded onto said "complex component". Preferably, said step of molding is performed directly only on the hollow cylinder 51. Preferably, said step of molding is performed directly on the hollow cylinder 51 mounted to the rolling elements 55', 55" and the shaft 50.

[0087] Innovatively, the pump assembly largely fulfills its intended purpose by overcoming the typical problems of the prior art.

[0088] Advantageously, indeed, the pump assembly has the impeller and rotor assembly housed in the same chamber, both wetted by the cooling liquid.

[0089] Advantageously, the pump assembly has a solution in which high rotational speeds are ensured.

[0090] Advantageously, the pump assembly has aperfectly balanced shaft group.

[0091] Advantageously, the pump assembly has a simple and certain positioning of the impeller group, starting from the shaft of the shaft group, which is fixed in a unique position.

[0092] Advantageously, the pump assembly has the cantilevered impeller group, not requiring additional axial support beyond the one fixed end.

[0093] Advantageously, the pump assembly is usable both in volute body configurations and in configurations in which the volute is obtained on other vehicle components.

[0094] Advantageously, the pump assembly is quiet, having solved the problem of the noise caused by the incorrect positioning of the blade element.

[0095] Advantageously, the pump assembly has a simple construction.

[0096] Advantageously, the pump assembly is easy to assemble.

[0097] Advantageously, the pump assembly is compact in size.

[0098] It is apparent that, in order to meet contingent needs, those skilled in the art may make changes to the above-described invention, all contained within the scope of protection as defined by thefollowing claims.

Claims

CLAIMS1. A pump assembly (1) for a cooling system of an operating assembly of a vehicle, which extends with respect to an axis (X-X) and comprises: i) a container group (2), which comprises a container body (21) and an auxiliary body (22), wherein the container group (2) delimits a dry chamber (201) and a wet chamber (202) in the coupling between the container body (21) and the auxiliary body (22), wherein said wet chamber (202) comprises a central portion (202') along the axis (X-X) and the dry chamber (201) comprises an annular portion (201'), which surrounds said central portion (202'); ii) an impeller group (3) housed in the wet chamber (202), comprising a blade body (30); iii) an electric motor group (4) comprising a stator(41), housed in an annular portion (201') and a rotor(42), housed in a central portion (202'); iv) a shaft group (5), mainly housed in the wet chamber (202), comprising:- a shaft (50) extending along the axis (X-X) in the central portion (202') comprising a fixed end (500) engaged with the auxiliary body (22);- two rolling elements (55', 55") axially spaced apart along the axis (X-X) engaged radially internally with theshaft (50) and radially externally by the rotor (42) and the impeller group (3), so that the rotor (42) and the impeller group (3) freely rotate with respect to the shaft (50).

2. Pump assembly (1) according to claim 1, wherein the shaft group (5) comprises a hollow cylinder (51) extending along the axis (X-X) engaged internally by the two rolling elements (55', 55") and externally by the rotor (42) and the impeller group (3).

3. Pump assembly (1) according to claim 2, wherein the hollow cylinder (51) has an outer surface (511) on which the rotor (42) is mounted, preferably by force coupling.

4. Pump assembly (1) according to claim 2 or 3, wherein the impeller group (3) is co-molded on the hollow cylinder (51) and the rotor (42).

5. Pump assembly (1) according to any one of the claims 2 to 4, wherein the hollow cylinder (51) is sealingly closed at the axial ends by the two rolling elements (55’, 55").

6. Pump assembly (1) according to any one of the preceding claims, wherein the rotor (42) and the hollow cylinder (51) have substantially the same axial dimension along the axis (X-X).

7. Pump assembly (1) according to any one of the preceding claims, wherein the impeller group (3)comprises a command body (35) extending lengthwise along the axis (X-X) from the blade body (30) suitable for at least partially containing the rotor (42).

8. Pump assembly (1) according to claim 7 and any one of claims 2 to 6, wherein the command body (35) extends radially from the hollow cylinder (51) and contains the rotor (42) therein.

9. Pump assembly (1) according to any one of the preceding claims, wherein the shaft group (5) comprises inner retaining elements, for example an inner hollow cylinder (52) or an annular protrusion (505), engaged by the two rolling elements (55', 55").

10. Pump assembly (1) according to any one of the preceding claims, wherein each rolling element (55', 55) is a ball bearing, a roller bearing or a taper bearing.

11. Pump assembly (1) according to any one of the preceding claims, wherein the container group (2) comprises a volute body (23), suitable for engaging the container body (21) and / or the auxiliary body (22), wherein the container group (2), in the coupling between the volute body (23) and / or the container body (21) and / or auxiliary body (22), delimits superiorly in the wet chamber (202) an impeller portion (202") in which the impeller (3) is housed.

12. A method of manufacturing a pump assembly (1)according to any one of the preceding claims, comprising the steps of:- engaging the rotor (42) with the rolling elements (55', 55") of the shaft group (5); - co-molding the impeller group (3) onto the rotor (42) and shaft group (5).

13. Method of manufacturing a pump assembly (1) according to claim 12, wherein the rolling elements (55', 55") engage the rotor (42) directly.

14. Method of manufacturing a pump assembly (1) according to claim 12, in combination with any one of claims 2 to 6, wherein the rolling elements (55', 55") engage the rotor (42) through the hollow cylinder (51).

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