Axial Gap Water Pump Motor With Thin-Film Waterproof Air Gap
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Solution Overview
Problem
Conventional water pumps using rare-earth magnets face challenges with increased production costs, magnetic flux loss, and noise/vibration due to air gaps and non-optimal stator core designs, necessitating the use of expensive rare-earth magnets and additional components for electromagnetic compatibility.
Innovation Solution
The water pump employs an axial gap-type electric motor with a ferrite magnet, minimized air gap using a thick-film waterproof partition wall and ultra-thin waterproof coating film, and optimized stator core design with soft magnetic composites (SMC) to reduce leakage flux and noise/vibration, while maintaining magnetic energy equivalent to rare-earth magnets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a waterproof can or injection mold is used to prevent water from entering the stator, then the stator is protected from water, but the air gap between the rotor and stator core is increased, causing magnetic flux loss
Solution Approach 1:
The patent applies a thin waterproof film (0.05-0.2mm thickness) instead of a thick waterproof can to separate the stator from water. This thin film structure provides waterproof protection while minimizing the air gap between the rotor and stator core, thereby reducing magnetic flux loss and maintaining motor efficiency.
2Power
If rare earth magnets are used to achieve desired magnetic energy, then the motor performance is improved, but the production cost increases
Solution Approach 1:
The patent changes the magnetic material parameter from rare earth magnets to ferrite magnets, and compensates for the lower magnetic energy density by optimizing the air gap dimension and stator core design. This parameter substitution approach achieves the desired motor performance while significantly reducing production costs.
Solution Approach 2:
The patent applies local optimization to the stator core design, specifically shaping the stator core teeth to concentrate magnetic flux in critical areas. This local quality enhancement compensates for the lower magnetic strength of ferrite magnets, maintaining overall magnetic energy while using cost-effective materials.
3Loss of energy
If the air gap is reduced to minimize magnetic flux loss, then motor efficiency is improved, but the rotor and stator require precise positioning, increasing manufacturing complexity
Solution Approach 1:
The patent introduces a thin waterproof film as an intermediary element between the rotor and stator core. This film serves as both a waterproof barrier and a positioning element that maintains a precise, minimal air gap. The film's flexibility and thinness allow for accurate dimensional control while simplifying manufacturing compared to rigid precision positioning structures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design achieves efficiency and torque comparable to rare-earth magnet systems, reduces manufacturing costs, and minimizes noise and vibration by utilizing a ferrite magnet with a minimized air gap and optimized stator core shape, enhancing overall motor performance.
Implementation Method 1
a stator arranged in a lower space formed by the body case and an upper cover, and generating a rotating magnetic field to rotatably drive the rotor
Implementation Method 2
a waterproof coating film made of a thinner film than the waterproof partition wall is formed at the front end portion of the plurality of teeth exposed to the fluid flow passage
Data Source
AI summary
Provided is a water pump using an axial gap-type electric motor employing a rare-earth-free magnet. The water pump (EWP) includes: a pump housing having a space in a sealing state on one side thereof, in which, on the other side thereof, an inlet through which a fluid is introduced and an outlet through which the introduced fluid is discharged are connected through a fluid flow passage; a rotor rotatably supported on the fluid flow passage; an impeller integrally formed with the rotor on the upper side of the rotor; a stator arranged in the lower space to generate a rotating magnetic field to rotatably drive the rotor; and a waterproof partition wall arranged inside the pump housing to separate the rotor from the stator.