Modular fluid pumps for use in a variety of applications

Abstract

To provide a motor in which wiring between a printed circuit board and windings can save time, expense and resources.SOLUTION: A motor comprises: a stator 12 having a plurality of stator teeth and a plurality of windings that is positioned on the stator teeth; a rotor having a central shaft and a plurality of magnets that defines electromagnetic communication with the windings; a housing surrounding the stator and including a fixed end cap; and a printed circuit board 142 that is attached to the fixed end cap at structural posts 150. Each of the windings defines a continuous wire that directly attaches to the printed circuit board without use of an intermediate terminal.SELECTED DRAWING: Figure 7

Description

[Technical Field]

[0001] The present invention relates generally to oil and water pumps, and more particularly to water or oil pumps that can be used in a variety of applications spanning a wide range of possible power outputs and have a modular configuration that can be generally customized to the ideal performance point for a particular application while maximizing common use of components and manufacturing equipment. [Background technology]

[0002] Water and oil pumps are used in various industries to lubricate, cool, or pressurize hydraulic ports. Such pumps can be tailored to fit specific applications, resulting in various components being essentially custom-designed for each specific design. These pumps are typically driven by electric motors. Many automotive applications, including hybrid and electric vehicles, require highly efficient operation to minimize power draw from the battery and extend the vehicle's operating range while cooling, lubricating, or pressurizing hydraulic ports. These pumps typically must fit into limited spaces and are difficult to package with electrical connections. Generally, the suction and pressure ports in these applications are unique to each pump / motor combination and the drive customization between the motor and pump elements. The present invention provides a scalable electric pump design that includes a pump element, a motor element, and an electrical circuit controller element that can convert electrical energy input to hydraulic energy output for lubrication, cooling, or hydraulic pressure. This electric pump design allows for flexibility in connector location and hydraulic output depending on the orientation of the motor and pump portions during assembly. Summary of the Invention

[0003] According to one aspect of the present invention, a modular fluid pump includes a stator having a plurality of stator teeth and windings positioned on the stator teeth. A rotor has a central shaft, substantially hemispherical ends, and a plurality of magnets that define electromagnetic communication with the windings. A housing surrounds the stator and includes a fixed end cap that receives one of the hemispherical ends of the central shaft and defines the axis of rotation of the rotor. A fixed end cap that receives the other hemispherical end of the central shaft. The central shaft and the fixed and fixed end caps define the axis of rotation of the rotor. Engagement of the hemispherical end with the central shaft and the fixed and fixed end caps maintains the rotor and central shaft aligned with the axis of rotation and balanced within the stator.

[0004] According to another aspect of the present invention, a method for forming a modular fluid pump includes forming an overmolded stator having a plurality of retainer dowels extending from an end of the overmolded stator. The method also includes forming a rotor having a metallic central shaft and a plurality of magnet pockets, positioning rotor magnets within the magnet pockets, magnetically attaching first bearing balls to a recessed end of the central shaft, positioning the bearing balls and the central shaft to engage recessed seats in a fixed end cap defined within the housing, securing a pump body to the overmolded stator, and securing a gerotor to the central shaft. The gerotor at least partially positions the central shaft and rotor along the axis of rotation. A second bearing ball is positioned on the other recessed end of the central shaft. A fixed end cap is rotationally secured onto the dowels to secure the pump body and gerotor to the overmolded stator. A fixed end cap and a fixed end cap secure the first and second bearing balls and the central shaft within the axis of rotation.

[0005] According to another aspect of the present invention, a modular fluid pump includes a stator having a plurality of stator teeth and windings positioned on the stator teeth. A rotor having a central shaft with a concave end that receives bearing balls. The rotor includes a plurality of magnets that define electromagnetic communication with the windings. A housing surrounding the stator includes a first fixed end cap that receives one of the bearing balls of the central shaft and defines a rotational axis of the rotor. The fixed end cap receives the other bearing ball of the central shaft. The central shaft and the first fixed and fixed end cap define the rotational axis of the rotor. Engagement of the bearing ball of the central shaft with the first fixed and fixed end cap maintains the rotor and central shaft aligned with the rotational axis and balanced within the stator. The fixed end cap and housing selectively define a plurality of locking positions that secure the fixed end cap to the housing.

[0006] According to another aspect of the present invention, a modular fluid pump includes a rotor having a central shaft with a hemispherical end and a plurality of magnets. A housing is overmolded onto a stator. The housing has a first end cap including a printed circuit board. The first end cap receives one of the hemispherical ends of the central shaft. A pump body has a gerotor coupled to the rotor. Movement of the rotor operates the gerotor to move fluid from an inlet to an outlet. A plurality of retainer dowels extend through the housing and the pump body. The fixing end cap includes an integrated twist-lock mechanism that cooperatively engages with the plurality of retainer dowels to define a locking position of the fixing end cap without additional fasteners. The locking position is defined by one of a plurality of rotational positions of the fixing end cap relative to the rotational axis of the printed circuit board and the rotor. The fixing end cap receives the other hemispherical end of the central shaft. The locking position of the fixing end cap is further defined by the secure engagement of the housing, the pump body and the fixing end cap.

[0007] According to another aspect of the present invention, a modular fluid pump includes a stator having a plurality of stator teeth and windings positioned on the stator teeth. The rotor has a central shaft with a concave end that receives bearing balls. The rotor includes a plurality of magnets that define electromagnetic communication with the windings. A housing surrounds the stator and includes a first end cap that receives one of the bearing balls of the central shaft and defines the rotor's axis of rotation. A fixed end cap receives the other bearing ball of the central shaft. The central shaft and the fixed and fixed end caps define the rotor's axis of rotation. Engagement of the bearing balls of the central shaft with the fixed and fixed end caps maintains the rotor and central shaft aligned with the axis of rotation and balanced within the stator. Motion of the rotor generates a fluid flow through the housing and between the rotor and the stator. The fluid flow engages the bearing balls to define viscous fluid cushions at least between the bearing balls and the first end cap and the fixed end cap, respectively.

[0008] According to another aspect of the present invention, a modular fluid pump includes a rotor having a central shaft with hemispherical ends and a plurality of magnets. A housing is overmolded onto a stator. The housing has a first end cap including a printed circuit board. The first end cap receives one of the hemispherical ends of the central shaft. A pump body has a gerotor coupled to the rotor. Movement of the rotor operates the gerotor to move fluid from the inlet to the outlet. A plurality of retainer dowels extend through the housing and the pump body. The fixing end cap includes an inlet, an outlet, and an integrated twist-lock mechanism that cooperatively engages with the plurality of retainer dowels to define a locking position of the fixing end cap without additional fasteners, where the locking position defines a secure engagement between the housing, the pump body, and the fixing end cap. The locking position is further defined by one of a plurality of rotational orientations of the fixing end cap's inlet and outlet relative to the printed circuit board.

[0009] According to another aspect of the present invention, a motor includes a stator having a plurality of stator teeth and a plurality of windings positioned on the stator teeth. A rotor has a central shaft and a plurality of magnets that define electromagnetic communication with the windings. A housing surrounds the stator and includes a fixed end cap. A printed circuit board is attached to the fixed end cap at structural posts. Each winding of the plurality of windings defines a continuous wire that attaches directly to the printed circuit board without the use of intermediate terminals.

[0010] These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon review of the following specification, claims, and accompanying drawings. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a cross-sectional view of one embodiment of a fluid pump including a modular structure. [Figure 2] FIG. 1 is a side view of a stator lamination stack used in a modular oil pump or modular water pump. [Figure 2A] End view of Figure 2. [Figure 3] 3 is a side view of the modular oil pump or modular water pump of FIG. 2 showing posts and wire securing features positioned on the end plates of the stator laminations. [Figure 3A] End view of Figure 3. [Figure 4] 4 is a side view of the stator of FIG. 3 showing a plan view and an elevation view of the stator of FIG. 3 with windings disposed on the teeth of the stator. [Figure 4A] End view of Figure 4. [Figure 5] 5 is a side view of the stator of FIG. 4 showing a plurality of retainer dowels coupled with the stator for securing a pump body and a customizable end cap of a modular oil pump or modular water pump. [Figure 5A] End view of Figure 5. [Figure 6]6 is a side view of the stator of FIG. 5 showing a printed circuit board positioned on the stator. [Figure 6A] End view of Figure 6. [Figure 7] 7 is a side view of the stator of FIG. 6 showing the positioning of the wires of the various windings positioned on the printed circuit board. [Figure 7A] End view of Figure 7. [Figure 8] FIG. 2 is a cross-sectional view of the stator laminations, rotor, and retainer dowels. [Figure 8A] FIG. 2 is a cross-sectional view of the stator laminations, rotor, and retainer dowels. [Figure 9] 1 is a schematic cross-sectional view of one embodiment of a stator showing the positioning of bearing balls configured to be a bearing assembly for a rotor of a modular fluid pump. [Figure 10] 1A and 1B show cross-sectional views of the rotor itself and the rotor positioned within one embodiment of a stator, respectively, and the configuration of the rotor positioned between first and second bearing balls. [Figure 10A] 1A and 1B show cross-sectional views of the rotor itself and the rotor positioned within one embodiment of a stator, respectively, and the configuration of the rotor positioned between first and second bearing balls. [Figure 11] 2 is a cross-sectional view of one embodiment of the modular fluid pump of FIG. 1 and illustrates the installation of at least one seal assembly. [Figure 11A] 12 is a cross-sectional view of the central shaft of FIG. 11 taken along line XIA-XIA. [Figure 12] 2 is a cross-sectional view of the modular fluid pump of FIG. 1 showing the mounting of the pump body with the rotor at least partially held on the bearing balls and aligned along the axis of rotation. [Figure 12A] 2A-2C are top views of the modular fluid pump of FIG. 1 showing the mounting of the pump body with the rotor at least partially held on the bearing balls and aligned along the axis of rotation; [Figure 13] 13 is a cross-sectional view of the modular fluid pump of FIG. 12 and illustrates the installation of the gerotor within the pump body. [Figure 14] 14 is a cross-sectional view of the modular fluid pump of FIG. 13 showing the installation of a separate seal assembly. [Figure 15] FIG. 10 shows a bottom view of the locking end cap positioned on the retainer dowel and rotationally fixed on the pump body, as well as one aspect of a pressure bias coupling to keep the rotor within the rotating shaft and supported at each end by bearing balls. [Figure 15A] 16 is a cross-sectional view of the fastening end cap of FIG. 15 taken along line XVA-XVA. [Figure 16] 14 is a cross-sectional view of the modular fluid pump of FIG. 13 and illustrates the rotational application of the second end cap onto the retainer dowels in a manner that does not include a separate fastener. [Figure 17] 1 is a linear flow diagram illustrating a method for forming a modular fluid pump. [Figure 18] FIG. 1 is a bottom perspective view of a stator lamination stack used in a modular pump. [Figure 19] FIG. 19 is a top perspective view of the laminate stack of FIG. 18. [Figure 20] FIG. 20 is a top perspective view of the laminate stack of FIG. 19 with windings and terminal wires attached thereto. [Figure 21] 21 shows an enlarged perspective view of the lamination stack and windings of FIG. 20, as well as the terminal wires located within the anchoring tower. [Figure 22] 22 is a side perspective view of the laminate stack of FIG. 21 and showing the installation of the retainer dowels. [Figure 23] FIG. 10 is a side view of one embodiment of a retainer dowel. [Figure 24] FIG. 1 is a bottom perspective view of the laminate stack shown with the printed circuit board attached and the terminal wires soldered to the printed circuit board. [Figure 25] FIG. 25 is an enlarged perspective view of the printed circuit board and laminate stack of FIG. 24. [Figure 26] 1 shows a schematic diagram of the top and bottom surfaces of a printed circuit board and various cooling and mounting zones within the printed circuit board. [Figure 27]FIG. 1 is a top perspective view of an overmolded stator of a modular pump. [Figure 28] FIG. 28 is a top perspective view of the overmolded stator of FIG. 27. [Figure 29] FIG. 1 is an exploded perspective view of the overmolded stator, rotor, and bearing balls of a modular pump. [Figure 30] 10A-10C are plan views of various embodiments of the central shaft and rotor implementing various materials and configurations. [Figure 31] 10A-10C are plan views of various embodiments of the central shaft and rotor implementing various materials and configurations. [Figure 32] 10A-10C are plan views of various embodiments of the central shaft and rotor implementing various materials and configurations. [Figure 33] Schematic diagrams of a range of rotor configurations used within a scalable embodiment of a modular pump. [Figure 34] FIG. 1 is a top perspective view of a rotor mounted within an overmolded stator of one embodiment of a modular pump. [Figure 35] FIG. 10 is a top perspective view of one embodiment of a modular pump showing the connection of the pump body with the retainer dowels in the overmolded stator. [Figure 36] FIG. 1 is a bottom perspective view of the pump body showing the separation paddles that separate the pressure side from the suction side within the rotor cavity. [Figure 37] 36 is a cross-sectional perspective view of the modular pump of FIG. 35 taken along line XXXVII-XXXVII. [Figure 38] FIG. 10 is a top perspective view of one embodiment of a modular pump showing the concave end of the central shaft and the bearing balls located on the concave end of the central shaft. [Figure 39] FIG. 10 is a top perspective view of one embodiment of a modular pump showing the concave end of the central shaft and the bearing balls located on the concave end of the central shaft. [Figure 40] FIG. 10 is a bottom view of a locking end cap incorporating one embodiment of a bias fitting and retention slots for attachment to the remainder of the modular pump. [Figure 41]FIG. 10 is a perspective view of a bias joint incorporated into the fixed end cap. [Figure 42] FIG. 10 is a perspective view of a bias joint incorporated into the fixed end cap. [Figure 43] FIG. 1 is a side perspective view of one embodiment of a modular oil pump or modular water pump. [Figure 44] FIG. 1 is a first side perspective view of one embodiment of a modular fluid pump. [Figure 45] FIG. 10 is another side perspective view of an embodiment of a modular fluid pump. [Figure 46] FIG. 1 is a bottom perspective view of one embodiment of a modular fluid pump. [Figure 47] FIG. 10 is another bottom perspective view of an embodiment of a modular fluid pump. [Figure 48] FIG. 1 is a first side view of one embodiment of a modular fluid pump. [Figure 49] FIG. 49 is a second side view of the modular fluid pump of FIG. 48; [Figure 50] FIG. 49 is a third side view of the modular fluid pump of FIG. 48; [Figure 51] FIG. 49 is a fourth side view of the modular fluid pump of FIG. 48; [Figure 52] FIG. 49 is a plan view of the modular fluid pump of FIG. 48. [Figure 53] 49 is a bottom view of the modular fluid pump of FIG. 48. [Figure 54] 53 is a cross-sectional view of the modular fluid pump of FIG. 52 taken along line LIV-LIV. [Figure 55] 53 is a cross-sectional view of the modular fluid pump of FIG. 52 taken along the line LV-LV. [Figure 56] 53 is a cross-sectional view of the modular fluid pump of FIG. 52 taken along line LVI-LVI. [Figure 57] 1 illustrates a cross-sectional view of one embodiment of a modular fluid pump and fluid channels disposed within a rotor housing of the fluid pump. [Figure 58] FIG. 49 is a first exploded perspective view of the modular fluid pump of FIG. 48; [Figure 59] FIG. 49 is another exploded perspective view of the modular fluid pump of FIG. 48; DETAILED DESCRIPTION OF THE INVENTION

[0012] For purposes of this description, the terms "top," "bottom," "right," "left," "rear," "front," "vertical," "horizontal," and their derivatives refer to the invention in the orientation of FIG. 1. However, it is to be understood that the invention may assume various alternative orientations, unless expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the accompanying drawings and described in the following specification are merely exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics related to the embodiments disclosed herein are not to be considered limiting, unless expressly recited in the claims.

[0013] As illustrated in Figures 1-16 and 18-59, reference numeral 10 generally refers to a modular fluid pump 10 that can be used in a variety of fluid assemblies to move materials of various viscosities, such as oil, water, and other similar materials, from one reservoir to another. The modular fluid pumps 10 can be fabricated to include a variety of standard features included within each modular fluid pump 10, along with a variety of custom or optional features that can be added to the modular fluid pump 10 depending on the particular application or design tolerances.

[0014] Referring again to Figures 1-16 and 18-59, the modular fluid pump 10, or other similar motors for non-fluid applications, may include a stator 12 having a plurality of teeth 13 and windings 16 positioned on the teeth 13 of the stator 12 to form poles 14 of the stator 12. A rotor 18 includes a central shaft 20 with substantially hemispherical ends 30 positioned at each shaft end 22 of the central shaft 20. A plurality of rotor magnets 84 are included that define electromagnetic communication with the windings 16 when the windings 16 are energized with electrical current. A housing 26 surrounds the stator 12 and includes a first fixed end cap 28 that receives at least one of the hemispherical ends 30 of the central shaft 20 and defines an axis of rotation 32 of the rotor 18. A second fixed end cap 34 is adapted to receive a portion of the central shaft 20 of the rotor 18 and maintain the central shaft 20 along the axis of rotation 32. The central shaft 20 and the fixed and retaining end caps 28, 34 cooperatively serve to define the axis of rotation 32 of the rotor 18. Engagement of one of the hemispherical ends 30 of the central shaft 20 with the fixed end cap 28 serves to maintain the rotor 18 and central shaft 20 aligned with the axis of rotation 32 and balanced within the poles 14 of the stator 12. A separate fixed end cap 34 may be positioned to engage the opposing hemispherical end 30 of the central shaft 20. The fixed end cap 34 engages the opposing hemispherical end 30 to secure the central shaft 20 between the two hemispherical ends 30 and along the axis of rotation 32 of the modular fluid pump 10.

[0015] In certain embodiments, it is contemplated that the fixing end cap 34 may include various custom features 36 that may be modified for a particular application. In this manner, the fixing end cap 34 may be added to the modular fluid pump 10 to adapt the modular fluid pump 10 to be useful in a wide range of applications and design conditions.

[0016] 1-16 and 18-59, the hemispherical end 30 of the central shaft 20 is defined by separate first and second bearing balls 38 positioned in the recessed end 40 of the central shaft 20. In this manner, the recessed end 40 of the central shaft 20 forms a tight engagement with the surface of each bearing ball 38. This tight engagement enables substantially smooth movement between the bearing balls 38 and each of the fixed and stationary end caps 28, 34. Furthermore, as will be discussed more fully below, movement of the flow 42 of fluid 44 through the modular fluid pump 10 can also cause a quantity of the flow 42 of fluid 44 to accumulate between the engagement of the bearing balls 38 and the recessed end 40, as well as between the bearing balls 38 and the recessed seats 46 formed in the fixed and stationary end caps 28, 34 of the modular fluid pump 10. In this manner, the fluid 44 may form a viscous cushion 48 or barrier between the bearing balls 38 and direct engagement with other components of the modular fluid pump 10. By using this viscous cushion 48 of fluid 44 between the bearing balls 38 and other components, wear between the rotor 18, the bearing balls 38, and other components of the modular fluid pump 10 may be reduced or substantially eliminated.

[0017] In one exemplary embodiment of the device, the bearing balls 38 may include 52100 chrome molybdenum steel bearing balls having a tight tolerance grade and a mirror finish. It should be understood that the bearing balls 38 may include a variety of other sizes depending on the design of the modular fluid pump 10.

[0018] 1-16 and 18-59, the recessed seat 46 of the overmolded stator 12 may be integrally formed from the overmold compound 172. The recessed end 40 of the central shaft 20 is typically circular or spherically concave in configuration and is integrally formed from or otherwise defined within the powder metal material of the central shaft 20. As discussed above, the recessed seat 46 and recessed end 40 that retain the bearing balls 38 are hemispherical in shape and adapted to maintain a consistent film of fluid 44 to maintain a viscous lubrication cushion 48 around the bearing balls 38 and reduce component wear.

[0019] According to various embodiments of the device, as illustrated in FIGS. 24-28 , the stator 12 and printed circuit board (PCB) 142 are overmolded with an overmolding compound 172, which may include a low-pressure, low-temperature moldable thermosetting composite. It is contemplated that the overmolding shape on the PCB 142 may include standard geometries sufficient to cover any one of various configurations of the electrical components of the PCB 142. Using standard geometries such as a cube, cone, or cylindrical prism, a single tool may be utilized to overmold a wide range of configurations of the PCB 142. Within the modular fluid pump 10, this molding process is typically used to set the various integrated functional features of the modular fluid pump 10. These features may include, but are not limited to, establishing cooling zones 144 within the PCB 142 to cool the various electrical components 152, protecting the electrical components 152 from damage and / or contamination, forming integral bearing pockets 146 for receiving bearing balls 38, creating grooves 174 that allow for active flow 42 of fluid 44 in the form of secondary flow 194 of fluid 44 through secondary flow paths 192, locating a temperature sensor 178 or a receptacle for receiving a sensor 178 on the board to detect the temperature of the fluid 44 moving through the secondary flow paths 192, and creating a reference surface that allows for a fastener-free design. This fastener-free design refers to the engagement between the retainer dowels 140 and the securing end caps 34, which will be described more fully below. Additionally, the overmolding of the printed circuit board 142 may define various keepout zones 148 where various components are attached to the printed circuit board 142.

[0020] Referring again to FIGS. 1 , 11-16 , 40-42 , and 54-59 , the recessed seats 46 defined in the fixed end cap 28, and in some embodiments the fixed end cap 34, may be in the form of hemispherical sockets adapted to receive a portion of the bearing balls 38 at each respective shaft end 22 of the central shaft 20 of the rotor 18. Using this configuration, a certain amount of clearance or play in the rotor 18 positioned between the opposing hemispherical sockets may be present in the modular fluid pump 10 having the fixed end cap 34. To offset this generally axial clearance between the opposing recessed seats 46, the fixed end cap 34 may include a pressure bias fitting 60 that at least partially surrounds the bearing balls 38 positioned near the fixed end cap 34. According to various aspects of the device, the pressure bias fitting 60 is disposed between the stator 12 and the rotor 18 and in communication with a fluid 44 flow passage 62 extending through a portion of the modular fluid pump 10.

[0021] Referring again to FIGS. 1 , 11-16 , 40-42 , and 54-59 , during operation of the modular fluid pump 10 (rotation of the rotor 18 within the stator 12), a flow 42 of fluid 44 is generated through the flow passage 62. This flow 42 of fluid 44 through the flow passage 62 generates an axial pressure 64 within the pressure bias fitting 60. The faster the rotor 18 rotates, the faster the flow 42 of fluid 44 will flow through the flow passage 62. The increase in flow rate 42 of fluid 44 can then result in an increase in pressure 64 exerted against the bearing ball 38 within the pressure bias fitting 60. The pressure bias fitting 60 includes a pressure channel 66 that directs this pressure 64 axially, typically along the axis of rotation 32 toward the bearing ball 38. In various embodiments of the device, the bearing ball 38 can be at least partially located within the pressure channel 66 of the pressure bias fitting 60. This axial pressure 64 compresses the bearing balls 38 near the stationary end cap 34 into the central shaft 20 and along the axis of rotation 32. This axial pressure 64 then forces the central shaft 20 against the lower bearing balls 232 and into the stationary end cap 28. Using the pressure 64 generated by the flow 42 of fluid 44 through the flow passages 62, the axial pressure 64 may axially secure the rotor 18 within the stator 12, preventing gaps, wobble, or other undesired displacement of the rotor 18 away from or eccentric to the axis of rotation 32.

[0022] As illustrated in at least FIGS. 35-59 , the pressure bias fitting 60 incorporates a bearing pocket 146 for receiving the upper bearing ball 234. The bias fitting 60 may be fabricated from powdered metal to provide a good and repeatable pocket geometry for receiving the upper bearing ball 234. The powdered metal also provides a porous surface finish that promotes retention of fluid 44, which travels through the flow passage 62 in the form of a viscous cushion 48, to lubricate the bearing balls 38, the bearing pocket 146, and the remainder of the bearing system, typically including the bearing balls 38, the central shaft 20, the fixed end cap 28, and the pressure bias fitting 60 of the fixed end cap 34.

[0023] Referring again to Figures 35-59, the pressure channel 66 of the bias fitting 60 is in the form of a small trough extending radially from the center fitting 68 of the bias fitting 60. Typically, the center fitting 68 is positioned opposite the bearing pocket 146. Through this configuration, when assembled into a manifold, the central pressure fitting 60 provides a bias pressure 64 as well as a small amount of fluid 44 leakage to the top of the bearing pocket 146. The pressure 64 at this interface is proportional to the pressure 64 generated by the gerotor 92 during use. The higher the forces within the modular fluid pump 10 near the gerotor 92, the proportionally higher the axial load on the central shaft 20 of the rotor 18 against the lower and upper bearing balls 232, 234, ensuring that the central shaft 20 of the rotor 18 remains centered within the bearing pocket 146 defined in the overmolded stator 12 and the retaining end cap 34. This configuration also ensures that there is a flow 42 of fluid 44 in contact with the bearing system. When forces within the modular fluid pump 10 are low, there is little or no axial load placed along the central shaft 20, particularly during start-up of the modular fluid pump 10, thereby providing easy start-up. This is especially true in modular fluid pump 10 applications that are sensorless.

[0024] According to various aspects of the device, the primary physical interface between the rotor 18 and housing 26 of the modular fluid pump 10 is between the bearing balls 38 located in the recessed ends 40 of the central shaft 20 of the rotor 18. As described above, using fluid 44 within the modular fluid pump 10, these recessed ends 40, as well as the hemispherical sockets of the recessed seats 46, can form a substantially continuous fluid viscous cushion 48 surrounding the lower and upper bearing balls 232, 234. This viscous cushion 48 can minimize friction and wear within the engagement between the lower and upper bearing balls 232, 234 and the central shaft 20 and the hemispherical sockets of the recessed seats 46. This fluid viscous cushion 48 prevents physical rubbing or direct physical contact between the central shaft 20 and the lower and upper bearing balls 232, 234, and between each bearing ball 38 and its respective recessed seat 46.

[0025] Referring again to Figures 1, 8-16, and 27-43, in forming the modular fluid pump 10, the components of each modular fluid pump 10 will generally be similar but may vary according to size and scale. As illustrated in Figure 33, it is contemplated that the modular fluid pump 10 may be made according to different sizes and scales, such that the modular fluid pump 10 may include, by way of non-limiting example, a small version, a medium version, and a large version, and each of these three versions may be made in three different heights, resulting in nine options available. It is also contemplated that additional versions of the modular fluid pump 10 may be provided, including additional heights and scales of the basic components of the modular fluid pump 10.

[0026] Additionally, as described more fully below, the modular fluid pump 10 may be configured to be positionable in a wide range of orientations and axes within a particular design configuration. Thus, the modular fluid pump 10 may be positioned in a variety of rotational orientations within a particular design, including but not limited to forward or rearward. Additionally, various wiring routes may be used in conjunction with jumper connections and other configurations that may provide multiple operating orientations of the modular fluid pump 10 in various axial configurations.

[0027] 1 , 8-16 , 29-43 , and 54-59 , the rotor 18 of the modular fluid pump 10 may include a central shaft 20 extending through a rotor body 80, which may be overmolded with plastic. The rotor body 80 may include a series of magnet channels or pockets 82 positioned parallel to the axis of rotation 32 of the rotor 18 for receiving rotor magnets 84 that provide electromagnetic communication between the rotor 18 and the windings 16 of the stator 12. These magnet pockets 82 in the rotor body 80 may be configured to receive various types of magnets 84.

[0028] As illustrated in FIGS. 8-14 and 54-59 , the central shaft 20 may include a plurality of locking geometries 86 that interact with the rotor body 80 and serve to hold the rotor body 80 in place relative to the central shaft 20. These locking geometries 86 may include a variable cross-sectional thickness that varies axially along the central shaft 20. The locking geometries 86 may also include flutes or ridges 88 defined within a portion of the central shaft 20. Because the rotor body 80 is typically molded around the central shaft 20, the rotor body 80 directly engages and is held within the locking geometries 86. This engagement axially and rotationally secures the rotor body 80 relative to the central shaft 20.

[0029] As shown in the exemplary embodiments of FIGS. 1-16 and 18-59 , these rotor magnets 84 disposed within the magnet pockets 82 of the rotor 18 may include at least one of sintered neodymium magnets, bonded neodymium magnets, bonded ferrite magnets, and other similar magnets 84 that may be used within the rotor 18 of the modular fluid pump 10. In addition to different types of magnets 84, the configuration of the magnets 84 may also be varied. Single-piece magnets 84, as well as magnets 84 made from a series of laminations, may be used within the rotor 18. The use of magnets 84 and variability in the types of magnets 84 for the rotor 18 may provide various strengths of magnetic force generated by the rotor 18. Different magnets 84 may be used to provide customizable electromagnetic communication and customizable rotational torque that may be generated by the rotor 18 when the various windings 16 are energized.

[0030] Referring again to Figures 11-16, 30-37, and 58 and 59, the central shaft 20 of the rotor 18 may include a double-D configuration including opposing planar surfaces 90 extending along at least a portion of the central shaft 20. The use of this "double-D" configuration, shown in cross section in Figure 11A, provides a consistent and efficient locking connection between the central shaft 20 of the modular fluid pump 10 and the gerotor 92. The double-D configuration also allows the central shaft 20 to be positioned within the molding tool in at least two configurations so that a single orientation is not required. The double-D configuration also provides torque locking of the magnets 84 relative to the central shaft 20. Furthermore, the use of the double-D configuration is important in this configuration, where the central shaft 20 is supported at each recessed end 40 by bearing balls 38. The double-D configuration is naturally symmetrical and can be centered along the axis of rotation 32 of the rotor 18. Therefore, balancing is not typically utilized in the design of the modular fluid pump 10.

[0031] Referring again to FIGS. 1 , 8-16 , 30-37 , and 54-59 , the central shaft 20 is typically made of a metallic material, such as powder metal. In some cases, the central shaft 20 may receive magnetic flux 100 from the magnets 84 of the rotor 18. In such a configuration, attachment of at least the lower bearing ball 232 may be achieved by a magnetic connection between the lower bearing ball 232 and the central shaft 20, which may be magnetically activated through the magnetic flux 100 received from the magnets 84. In this configuration, the lower bearing ball 232 may be magnetically coupled to the recessed end 40 of the rotor 18, which may be disposed within the stator 12 with the lower bearing ball 232 magnetically coupled thereto. In this manner, the central shaft 20 of the rotor 18 may function as an attachment tool for positioning the lower bearing ball 232 within the recessed seat 46 located at the base of the stator 12 and within the fixed end cap 28 of the housing 26.

[0032] 1-8 and 18-22, construction of the modular fluid pump 10 may include forming the stator 12 by aligning lamination stacks 120 that form the internal structure of the stator 12, including the teeth 13 of the stator poles 14. In certain embodiments, the individual laminations that make up the stator 12 include stitch-up sets 15 that function as alignment features to maintain the stack of laminations 120 in an aligned configuration. Thanks to these stitch-up sets 15, separate fasteners are not required to hold the stack of laminations 120 together during formation of the stator 12. Rather than having stitch-up sets 15, the top lamination may include apertures that receive vertically adjacent stitch-up sets 15. This configuration ensures that the top surface of the stack of laminations 120 is flat, without any protruding features that could misalign the end plate 122 or other portions of the assembly.

[0033] Typically, the stator 12 will be a three-phase stator 12 with three separate windings 16 wound around the teeth 13 to form various stator poles 14. While six stator poles 14 are shown in the exemplary illustration, it should be understood that other configurations of stator poles 14, as well as different phase configurations of the motor, may be utilized.

[0034] Once the laminations 120 of the stator 12 are completed, end plates 122 are placed on each end of the lamination stack 120 to secure the lamination stack 120 together. Typically, the end plates 122 are slip-fit ​​or press-fit onto opposite ends of the lamination stack 120. This configuration allows the stack of laminations 120 and the end plates 122 to not be tightly fastened together and can be separated by hand. It should be understood that rivets, bolts, welds, and other attachment mechanisms can be used to secure the lamination stack 120 together.

[0035] Once the lamination stack 120 is complete and the end plates 122 are in place, the windings 16 may be placed around the teeth 13 of the stator 12. Placing the windings 16 on the teeth 13 of the stack of laminations 120, as well as on the end plates 122, serves to secure the assembly together as a single stator 12. The stator 12 is configured with a three-phase winding, with three separate wires 136 wound around the teeth 13 of the stator 12 to form a predetermined configuration of poles 14. After the windings are complete, the terminal ends 130 of the wires 136 are secured within one of the end plates 122. The upper end plate 132 includes various fastening towers 134 that may receive the terminal ends 130 of the wires 136 of the windings 16. These fastening towers 134 may receive the various terminal ends 130 of the wires 136 and hold them in a particular position during the formation of the modular fluid pump 10. These wires 136 may be in the form of various U, V, and W wires 136 leading from the stator 12 and windings 16 of the stator 12, as well as ground wires 162 leading from the stator 12 and windings 16 of the stator 12. As discussed more fully herein, the rotational orientation of the lamination stack 120 relative to the fixing and fixing end caps 28, 34 is not critical and may be switched in 90 degree increments as needed for a particular design.

[0036] 5-6A and 22 , after the windings 16 are attached and the terminal ends 130 of the wires 136 are secured within the retaining towers 134, a plurality of retainer dowels 140 may be positioned through the lamination stack 120 and end plates 122 of the stator 12. As will be explained more fully below, these retainer dowels 140 are used to hold the retaining end caps 34 in place and secure the entire modular fluid pump 10 assembly, including the retaining end caps 34, which may include custom features 36 for use in a particular design. While a rectilinear geometry of the stator 12 and modular fluid pump 10 is shown, other polygonal geometries may be implemented to create an orientation-free design for the modular fluid pump 10.

[0037] 7, 8A, and 18-26, after the retainer dowels 140 are secured, the PCB 142 may be mounted on various locating features or structural posts 150 that position the PCB 142 in a spaced-apart arrangement away from the terminal section 130 and the securing towers 134 of the upper end plate 132. The PCB 142 may include various electrical components 152, which may include, but are not limited to, various microprocessors, field effect transistor (FET) drivers, drive transistors, temperature sensors 178, wiring terminals, and other similar features. As described more fully below, a portion of the fluid flow path 62 through the modular fluid pump 10 may pass near or in direct engagement with these electrical components 152 to provide cooling for these components during operation of the modular fluid pump 10.

[0038] 7, 8A, and 18-26, once the PCB 142 is positioned, the terminal portions 130 of the wires 136 of the windings 16 may be wound around the PCB 142 to wire terminals 154 located on the top surface of the PCB 142. In this manner, a single continuous wire 136 may form these windings 16 and terminal portions 130. Thus, the terminal portions 130 may be soldered directly to the PCB 142 at the wire terminals 154, eliminating the need for intermediate terminals between the windings 16 and the PCB 142. This configuration of the wiring between the windings 16 and the PCB 142 may save significant time, expense, and resources.

[0039] According to various aspects of the device, the terminations 130 of the wires 136 derived from the various windings 16 may be located on specific solder pads 156 within the PCB 142. A ground portion 160 of the PCB 142 is contemplated as dedicated solder pads 156 for attaching various ground wires 162 that may contact the stator 12. By separating the locations of the solder pads 156 for the ground wires 162 from the wire terminals 154 in the form of solder pads 156, the additional effort required to separate the wires 136 of the windings 16 from the ground wires 162 for the terminations 130 of the windings 16 is minimized and substantially eliminated. Because these separate wires 136 are typically located on opposite sides of the PCB 142, separate soldering operations within the separated solder pads 156 may ensure that short circuits do not occur between the terminations 130 of the windings 16 and the ground wires 162. The various solder pads 156 of the PCB 142 may be pre-tinned during the manufacture of the PCB 142 or at some time prior to the soldering operation that connects the wires 136 to the solder pads 156. Pre-tinning the solder pads may be accomplished by adding solder paste to the tinned pads 156. This solder paste may be disposed on the PCB 142 by spreading, brushing, dropping, or other similar treatment processes. In various embodiments of the device, the solder paste may be printed onto the PCB 142 using a printhead that deposits specific amounts of solder paste in specific and predetermined areas of the PCB 142.

[0040] Referring again to Figures 4-7A and 20-26, the placement of the wires 136 of the windings 16 and the attachment of these wires 136 to the solder pads 156 can be used in various embodiments of the modular fluid pump 10. Furthermore, this process of placing and securing the wires 136 within the stator 12 can be utilized in a wide variety of motors. Such motors can be used in fans, impellers, pumps, drive mechanisms, stepper motors, combinations thereof, and other similar types of motors. By way of example and not limitation, the use of strain reliefs 292 and grooves 292 to minimize strain on the wires 136 can be utilized in a wide variety of motor applications. Similarly, the use of a single continuous wire 136 for the windings 136 and terminations 130, without the use of intermediate terminals, and the placement of these integral terminations 130 on specific pre-tinned areas of the PCB 142, can also be utilized in a wide variety of motor-related applications. Furthermore, the various features of the modular fluid pump 10 described herein are applicable to a wide variety of motor applications.

[0041] 9-10A and 22-28, after the termination portions 130 of the windings 16 and the ground wires 162 are soldered to the appropriate portions of the PCB 142, the stator 12 structure is then overmolded with an overmolding compound 172 to insulate the various components of the stator 12. During this overmolding operation, the contacts of the ground wires 162 and the terminal wires 136 are allowed to protrude through the overmolding for connection with power and data wiring in the final installation of the modular fluid pump 10. The overmolding is performed such that the stator 12, and typically the controller assembly 170 (PCB 142) contained therein, contains various grooves 174 in the overmolding compound 172 that run the length of the inner diameter 230 of the rotor 18 between the poles 14 of the stator 12. These grooves 174 may also be located at the ends of the stator teeth 13. These grooves 174 in the overmold compound 172 of the stator 12 provide fluid channels 176 that provide flow 42 between the stator 12 and the rotor 18 to cool various components and various electrical components of the PCB 142. This flow 42 of fluid 44 through the grooves 174 in the areas between or near the poles 14 of the stator 12 also provides flow 42 of fluid 44 past thermistors or other types of temperature sensors 178 on the PCB 142, which are in thermal communication with secondary flow paths 194 that can be used to monitor the temperature of the fluid 44 being moved through the modular fluid pump 10, as well as the temperature of various components of the modular fluid pump 10. Additionally, these grooves 174 may allow movement of fluid 44 to one or both of the lower and upper bearing balls 232, 234 to provide the viscous fluid cushion 48 described above.

[0042] As illustrated in FIGS. 1 , 13-16 , 27-29 , and 43-59 , during operation of the rotor 18 within the stator 12, a primary flow 196 of fluid 44 is moved through the modular fluid pump 10, providing the primary movement of the viscous fluid 44 through the modular fluid pump 10. Grooves 174 formed by an overmold compound 172, typically in the form of some type of resin or other polymeric material, provide secondary flow paths 192 that divert a portion of the fluid flow 42 toward one or both of the PCB 142, the temperature sensor 178, and the bearing balls 38 of the modular fluid pump 10. It is contemplated that the secondary flow 194 of fluid 44 through the secondary flow paths 192 is sufficiently smaller than the primary flow 196 of fluid 44 so that the operation of the modular fluid pump 10 is not unduly reduced by moving the secondary flow 194 of fluid 44 through the secondary flow paths 192. The use of the secondary flow paths 192 provides a more efficient and consistent operation of the modular fluid pump 10. Additionally, the secondary flow path 192 is sufficiently small, ie, does not adversely degrade the performance of the modular fluid pump 10 .

[0043] The flow 42 of fluid 44 through primary and secondary flow paths 198, 192 is initiated by the action of gerotor 92. Gerotor 92 is directly connected to central shaft 20 such that, when modular fluid pump 10 is actuated, current is transferred through at least some of the windings 16 in stator 12. This activation of the windings generates an electromagnetic force (EMF) that rotates rotor 18 relative to poles 14 of stator 12. Because gerotor 92 is connected to rotor 18, the movement of rotor 18, in turn, actuates gerotor 92. Various flow pockets 210 created through the action of gerotor 92 provide movement of fluid 44 through inlet 212, through primary flow path 198 as well as secondary flow path 192, and into and through outlet 214 of modular fluid pump 10.

[0044] 11-15A and 29-39, after the stator 12 is overmolded, the rotor 18 may be positioned within the inner diameter 230 of the stator 12. As described above, the lower bearing ball 232 may be positioned within the recessed seat 46 of the fixed end cap 28 by placing the first or lower bearing ball 232 on the shaft end 22 of the central shaft 20, as well as the second or upper bearing ball 234. The central shaft 20 may be activated so that the magnetic flux 100 from the magnet 84 of the rotor 18 forms a magnetic field that may be used as the magnet 84 to retain the lower bearing ball 232. By magnetically attaching one or both of the bearing balls 38 to the recessed end 40 of the central shaft 20, the central shaft 20 may be used as a tool to position the lower bearing ball 232 within the recessed seat 46 defined in the fixed end cap 28 of the modular fluid pump 10.

[0045] Typically, the rotor 18 of the modular fluid pump 10 will include four magnets 84 that electromagnetically cooperate with the six poles 14 of the stator 12. If a different configuration of poles 14 of the stator 12 is included, the configuration of magnets 84 of the rotor 18 will typically also vary. Typically, the number of magnets 84 of the rotor 18 will differ from the number of poles 14 of the stator 12 such that when the windings 16 of the stator 12 are energized, the generated EMF within the stator 12 produces rotation of the rotor 18.

[0046] It is contemplated that various seal assemblies 110 may be included within the overmolded stator 12 and pump body 240 that holds the gerotor 92. The various seal assemblies 110 may hold O-rings 112 therein. The pump body 240 may be attached to the overmolded stator 12 and positioned on the retainer dowels 140. Within the pump body 240, the gerotor 92 at least partially positions and aligns the central shaft 20 and sets a rotational position to rotate the magnets 84 about the central shaft 20. As described above, the pump body 240 and gerotor 92 may be positioned at various rotational positions relative to the overmolded stator 12. It is contemplated that the positioning of the pump body 240 may determine which of the multiple grooves 174 or fluid channels 176 defined between (or along) the poles 14 of the stator 12 function as secondary flow paths 192 for the secondary flow 194 of the fluid 44.

[0047] By way of example and not limitation, pump body 240 may include an inlet 250 and an outlet 252 that define secondary flow path 192. Inlet 250 may align with a corresponding set of grooves 174 at each rotational position relative to the rectangular body of modular fluid pump 10. Thus, regardless of the positioning of pump body 240 and gerotor 92, pump body 240 and gerotor 92 will typically align with a corresponding set of grooves 174 defined adjacent poles 14 of stator 12. The orientation of pump body 240 and gerotor 92 may vary depending on the exact configuration of the device incorporating modular fluid pump 10.

[0048] In various aspects, it is contemplated that the precise orientation of pump body 240 may not be a critical consideration, such that the orientation of pump body 240 is not critical to forming modular fluid pump 10, so long as gerotor 92 is aligned with axis of rotation 32 of rotor 18. As explained more fully below, pump body 240 and locking end cap 34 are configured to be aligned with stator 12 and PCB 142 at multiple rotational positions. These rotational positions are typically in 90-degree increments corresponding to the placement of retainer dowels 140. Other degree increments may be utilized if the geometry of modular fluid pump 10 has other polygonal shapes.

[0049] As illustrated in Figures 34-42 and 54-59, gerotor 92 and pump body 240 form a cavity in gerotor 92 that at least partially defines primary flow path 198. Pump body 240 includes flow ports extending therethrough to direct pressure flow 42 of fluid 44 from the pressure side of gerotor 92 down grooves 174 that form secondary flow path 192, and the flow ports also allow pressure flow 42 of fluid 44 to return to the suction side of gerotor 92 through secondary flow path 192. Additionally, pump body 240 includes a wall of material that separates the pressure side of gerotor 92 from the suction side of gerotor 92, which wall of material serves to deflect flow 42 of fluid 44 into grooves 174 that form secondary flow path 192, thereby defining secondary flow 194 of fluid 44. This wall of material is typically stationary and may include one or more, typically two, paddles 242 positioned near the central shaft 20 of the rotor 18. These paddles 242, which extend downward from the pump body 240, separate the pressure side from the suction side within a rotor cavity 244. This serves to direct a secondary flow 194 of fluid 44 down the molded grooves 174 that define the secondary flow path 192. This secondary flow 194 of fluid 44 serves to lubricate the bearing balls 38 and cool the various components of the PCB 142. In addition to the secondary flow 194 of fluid 44, it is contemplated that an internal grease may also be utilized to provide lubrication to the internal components of the modular fluid pump 10.

[0050] Referring again to Figures 14-16, 35-39, and 54-59, after the pump body 240 and gerotor 92 are placed on the overmolded stator 12, the basic form 260 of the modular fluid pump 10 is substantially complete. This assembly may not be secured onto the retainer dowels 140. According to various aspects of the device, the locking end caps 34 of the modular fluid pump 10 may be rotationally secured onto the retainer dowels 140 to secure the components together and form the modular fluid pump 10. The retainer dowels 140 may include multiple lengths corresponding to various lengths of the stator 12. Also, retainer dowels 140 of various lengths fit pump bodies 240 and locking end caps 34 of various sizes.

[0051] 14-16 and 40-59, the fixing end cap 34 of the modular fluid pump 10 may include a standard side 270 that engages the pump body 240 and the gerotor 92. This standard side 270 may be of substantially similar configuration among various designs of modular fluid pumps 10. Opposite the standard side 270 is a custom side 272 where various components of a particular design will be mounted within the fixing end cap 34. On the standard side 270, one or more retention slots 274 may be defined within the material of the fixing end cap 34. These retention slots 274 may include eye slots that may receive the slotted ends 276 of the respective retainer dowels 140. Once the slotted end 276 of each retainer dowel 140 enters the eye of the retention slot 274, rotation of the locking end cap 34 moves the slotted end 276 of each dowel through the retention slot 274 and secures each slotted end 276 of the retainer dowel 140 within the corresponding retention slot 274.

[0052] It is also contemplated that the retention slots 274 included in the fixed end cap 34 may be angled such that rotation of the fixed end cap 34 also urges the fixed end cap 34 against each retainer dowel 140 and against the pump body 240 to compress the O-ring 112 in the seal assembly 110 and form a substantially fluid-tight fit that defines any one of a plurality of locking positions 278 of the fixed end cap 34. Various detents may be included in the retention slots 274 of the fixed end cap 34 to substantially secure the slotted end 276 of each retainer dowel 140 within a cooperating slot in the fixed end cap 34. In this manner, formation of the modular fluid pump 10 may be accomplished without the need for fasteners, such as bolts, screws, welds, and other attachment mechanisms and methods that may be used in conventional fluid pumps to secure components together.

[0053] Because the modular fluid pumps 10 are secured together through the twist-lock rotational engagement of the fixing end caps 34 and the retainer dowels 140, the number of holes that need to be drilled in the modular fluid pumps 10 is significantly reduced, as is the opportunity for leaks in the modular fluid pumps 10. Through this configuration, securing of the modular fluid pumps 10 may be achieved primarily through three components in the stack of modular fluid pumps 10: the overmolded stator 12, the pump body 240 (which mate to form the basic form 260), and a manifold, typically in the form of the fixing end caps 34 of the modular fluid pumps 10. Through the configuration of biasing or retention slots 274 in the fixing end caps 34, the twist-lock mechanism or configuration of the fixing end caps 34 provides a biased fit between the fixing end caps 34 and the pump body 240, holding the various components of the modular fluid pump 10 together. The pump body 240 and the locking end cap 34 include machined features so that these components can hold and carry the necessary tolerances within the modular fluid pump 10 .

[0054] 4-8A and 20-26, as mentioned above, the wires 136 extending from the windings 16 into the PCB 142 do not include intermediate terminals. The fastening towers 134 contained within the upper end plate 132 provide strain relief 290 on the windings 136 and also provide structural channels to guide the wires 136 from the windings 16 to the strain relief 290 on the end of the PCB 142. This strain relief 290 may include strain relief notches 292 located on the outer edge of the PCB 142. Structural support is also provided to the PCB 142 to fold and hold the wires 136 onto the PCB 142 while soldering to the pre-tinned solder pads 156. This structure of the PCB 142 is provided by heat stake posts 150 extending upward from the upper end plate 132 located at one end of the lamination stack 120 that forms the stator 12. These posts 150 are integrated into the top end plate 132 to provide support for the PCB 142. The heat stake posts 150 provide structure below the PCB 142 to support and prevent damage to the PCB 142 during manufacturing when various operations are performed on the PCB 142, such as soldering, folding wires 136, and other similar operations. Additionally, the space between the top end plate 132 and the PCB 142 defined by the heat stake posts 150 may provide at least a portion of a secondary flow path 192 through which a secondary flow 194 of the fluid 44 may travel to provide cooling to components of the PCB 142.

[0055] According to various aspects of the device, as illustrated in FIGS. 11-14 , it is contemplated that at least one flux collector pocket 310 may be disposed within the stator 12 after the windings 16 are positioned on the poles 14 of the stator 12, but before the overmold compound 172 covers the stator 12. These flux collector pockets 310 may function to transmit a magnetic field from the rotor 18 and direct this magnetic field to a Hall Effect sensor on the PCB 142. The Hall Effect sensor may be used for optional sensor communication to assess the rotational position of the rotor 18 relative to the stator 12. Under certain conditions, a flux collector pocket 310 may be attached to each design of the modular fluid pump 10. It should be understood that a flux collector is not required for every implementation of the modular fluid pump 10. In configurations where sensorless communication of the rotor 18 is desired, the flux collector pocket 310 may not be included within the stator 12.

[0056] Referring again to Figures 1-16 and 18-59, various configurations of the modular fluid pump 10 may include various standard components that most, if not all, implementations of the modular fluid pump 10 will typically include. Such components may include, but are not limited to, the rotor 18, the central shaft 20, and the rotor body 80 having the magnet pockets 82. As noted above, the exact configuration and materials of the magnets 84 of the rotor 18 may vary depending on the exact use and implementation of the modular fluid pump 10. The stator 12, poles 14, and windings 16 will typically be included as standard parts in each modular fluid pump 10 design. Additionally, the wires 136 and ground wires 162 for the windings 16 will also typically be included in each modular fluid pump 10 design, as will the connection to the PCB 142. The overmold compound 172 surrounding the stator 12, the retainer dowels 140, and the PCB 142 will also typically be standard components in each modular fluid pump 10 embodiment. Various custom features 36 may also be included within modular fluid pump 10. These custom features 36 may also include, as described above, the material of the magnets 84 disposed within magnet pockets 82 of rotor 18, the rotational position of gerotor 92 and pump body 240 relative to stator 12, the use of jumper connectors with PCB 142 to orient the position of modular fluid pump 10 in a particular application, and the precise configuration of the fixing end cap 34 or manifold. As described above, fixing end cap 34 may include a custom side 272 with various design-specific features useful for mounting or otherwise incorporating modular fluid pump 10 within a particular application, configuration, or design.

[0057] As illustrated in FIGS. 35-59 , the gerotor 92 is mounted within a pump body 240. In various embodiments of the device, the gerotor 92 of the modular fluid pump 10 may include multiple capacity configurations that can vary in thickness and / or diameter with corresponding changes to the configuration of the pump body 240. Accordingly, the modular fluid pump 10 may be designed with a variety of pump bodies 240 provided as extrusion blanks in different widths that match the corresponding widths of the stator 12. Typically, three different configurations of the pump body 240 will be provided to match the corresponding widths of the stator 12. The variable configurations of the pump body 240 and stator 12 allow flexibility in either the thickness of the pump body 240 or the pocket diameter of the gerotor, with simple changes to the machine program to accommodate the three configurations of the gerotor 92. After the gerotor 92 is mounted within the pump body 240, the upper bearing ball 234 is positioned in the recessed seat 46 at the end of the central shaft 20 of the rotor 18.

[0058] It is contemplated that through the use of modular fluid pumps 10, a single modular fluid pump 10 or a family of modular fluid pumps 10 may be manufactured. These modular fluid pumps 10 may be customized after manufacture for incorporation into a particular specific application or design. The customizable features included within the modular fluid pump 10 allow for changes in orientation, specific materials, axial configurations, and other aspects that allow the modular fluid pump 10 to be incorporated into a wide range of applications or designs.

[0059] 1-59 , having described various aspects of the modular fluid pump 10, a method 400 for manufacturing the modular fluid pump 10 is disclosed. According to the method 400, an overmolded stator 12 is formed having a plurality of retainer dowels 140 extending from an end of the overmolded stator 12 (step 402). A rotor 18 is also formed, including a metal central shaft 20 and a plurality of magnet pockets 82 or recesses (step 404). Next, a magnet 84 may be disposed within each magnet pocket 82 defined in the rotor 18 (step 406). Bearing balls 38 may be magnetically attached to the recessed end 40 of the central shaft 20 (step 408). As described above, positioning the magnets 84 within the rotor 18 may generate a magnetic flux 100 that provides the central shaft 20 with sufficient magnetism to hold the bearing balls 38 in place during installation of the rotor 18. According to method 400, bearing balls 38, typically lower bearing balls 232, are then positioned to engage recessed seats 46 of stationary end cap 28 (step 410). As described above, central shaft 20 is magnetically activated through magnetic flux 100 provided by rotor magnet 84, so that central shaft 20 can function as a tool to hold and position lower bearing balls 232 within recessed seats 46 of stationary end cap 28. Pump housing 26 may then be secured to overmolded stator 12 and retainer dowel 140 (step 412). Gerotor 92 is then secured to central shaft 20 within pump body 240 (step 414). Gerotor 92 at least partially positions central shaft 20 and rotor 18 along rotational axis 32. Stationary end cap 34 is then rotationally secured onto slotted end 276 of retainer dowel 140 (step 416). In this manner, the locking end cap 34 provides a twist-lock arrangement that secures the locking end cap 34 to the retainer dowel 140 without the use of additional fasteners.This fastener-free configuration of modular fluid pump 10 prevents unnecessary use of fastener holes and other apertures that may be included in conventional fluid pumps.

[0060] As illustrated in Figures 1-59, a manifold in the form of a locking end cap 34 is seated within the retainer dowels 140 and rotated into position to provide a compressive load on the remainder of the modular fluid pump 10, particularly the various O-rings 112. As discussed herein, the overmolded stator 12 can be assembled, typically in 90 degree increments, to position the electrical / data connector 320 on any side of the pump 40 without affecting the motor or hydraulic function of the modular fluid pump 10. Through this modular configuration of the modular fluid pump 10, various configurations of the pump 10 can provide a wide range of advantages. These benefits include, but are not limited to, a pressure range up to approximately 10 bar, a flow rate range up to approximately 14 liters / minute, a temperature range (exposed) from approximately -40°C to approximately 150°C, a functional range from approximately -40°C to approximately 125°C (duty and fluid dependent), voltage variants from 12VDC, 24VDC, and 48VDC, IP6K9K compliant sealing for indoor or outdoor applications, electromagnetic compatibility, sensor or sensorless configuration, communications capable of CAN, LIN, PWN, on / off, and other communication formats, in-vehicle temperature sensing, full diagnostic logging and recording, fault storage black box, low-noise construction, a flexible architecture to accommodate demanding packaging constraints, and provisions for customer-specific manifolds for flexible mounting configurations.

[0061] As described herein, the various components included within modular fluid pump 10, as well as the processes used to manufacture and operate modular fluid pump 10, may be utilized together in any one of a variety of fluid pump designs. In addition, these components and processes described herein may also be implemented in other types of motors, in both fluid-related and non-fluid-related designs and applications.

[0062] It is to be understood that changes and modifications can be made to the above-described structure without departing from the concepts of the present invention, and further that such concepts are intended to be covered by the following claims unless the language thereof expressly states otherwise.

Claims

1. A motor, a stator having a plurality of stator teeth and a plurality of windings positioned on the stator teeth; a rotor having a central shaft and a plurality of magnets that define electromagnetic communication with the windings; a housing surrounding the stator and including a fixing end cap; a printed circuit board attached to the fixed end cap at a structural post, wherein each winding of the plurality of windings defines a continuous wire that attaches directly to the printed circuit board without the use of an intermediate terminal; a plurality of retainer dowels extending through the stator and the housing; the plurality of retainer dowels are connected to a fixed end cap at one end of the stator and housing, the fixed end cap extends to an opposite end of the stator and housing, and connects to the plurality of retainer dowels without additional fasteners; Motor.

2. the plurality of retainer dowels projecting from the opposite sides of the stator and housing; The motor of claim 1 , wherein said locking end cap connects to said plurality of retainer dowels in a twist-lock rotational engagement.

3. 3. The motor of claim 2, wherein the locking end cap includes a plurality of retention slots that receive and rotationally secure the retainer dowels to compress the locking end cap, the rotor, the stator, and the housing together into a rigid assembly.

4. The motor of claim 2 , wherein the locking end cap is configured to be secured to the printed circuit board in a plurality of locking positions.

5. 2. The motor of claim 1, wherein the housing includes a printed circuit board containing electrical components and receiving wires from the plurality of windings, the printed circuit board including solder pads and strain relief notches that directly receive ends of each winding.

6. The motor of claim 5 wherein said solder pads comprise pre-tinned solder paste.

7. The motor of claim 6 , wherein the pre-tinned solder paste is printed onto the printed circuit board.

8. 2. The motor of claim 1, wherein the windings are soldered onto wire terminals of the printed circuit board and a ground wire is soldered to a ground portion of the printed circuit board.

9. The motor of claim 8 , wherein the wire terminal and the ground are located on opposite sides of a surface of the printed circuit board.

10. The motor of claim 2 , wherein the housing is defined by an overmolding compound that completely surrounds the stator, the housing being substantially orientation-neutral with respect to its position relative to the stationary end cap.

11. The motor of claim 2 , wherein the fixed end cap and the housing are capable of being fixed in a plurality of rotational positions relative to the axis of rotation of the rotor.

12. The motor of claim 11 , wherein the plurality of rotational positions are configured at 90 degree increments about the axis of rotation of the rotor.

13. A motor according to any one or more of the preceding claims, wherein the housing can be used in conjunction with jumper connectors to orient the stator and rotor in a plurality of operating orientations relative to an assembly receiving the housing.

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