Driver-Integrated BLDC Fuel Pump Module Flange Design
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Solution Overview
Problem
Conventional driver-separated BLDC fuel pump modules face spatial installation limitations and efficiency reductions due to voltage drops and increased wire length, leading to operational performance deterioration.
Innovation Solution
A driver-integrated type BLDC fuel pump module where the driver is installed in the flange, reducing wire length and eliminating the need for separate connectors, with a heat-dissipating protective cap made of aluminum or stainless steel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the driver and BLDC fuel pump module are separated and connected via electric wire, then the driver can be installed independently, but the spatial installation is limited and voltage drop occurs reducing operational efficiency
Solution Approach 1:
The driver is integrated directly into the flange of the BLDC fuel pump module, merging two previously separate components into a single unified assembly. This eliminates the need for external electric wire connections and removes spatial installation limitations while improving operational reliability by eliminating voltage drop issues.
2Adaptability or versatility
If the driver is mounted separately with long electric wire connection, then the installation location is flexible, but the voltage drop reduces operational efficiency
Solution Approach 1:
The driver is merged with the flange structure, eliminating long electric wire connections and reducing voltage drop. This integration maintains adaptability through the flange's mounting capabilities while significantly improving operational efficiency by minimizing energy loss in the electrical connection path.
3Reliability
If the driver is integrated in the flange, then the wire length is reduced eliminating voltage drop, but the flange structure becomes more complex
Solution Approach 1:
The driver is combined with the flange to create an integrated assembly that improves reliability by eliminating voltage drop. The complexity increase is managed by designing the driver to fit within the existing flange structure, utilizing the flange's inherent mounting surfaces and fastening mechanisms.
Solution Approach 2:
The flange is designed to serve multiple functions: its original mounting function for the fuel pump module plus a new function as a mounting platform for the driver. This multi-functionality approach adds driver integration capability without requiring a completely new structural design.
4Reliability
If the driver is mounted on the flange upper surface, then the wire length is minimized, but the heat dissipation becomes a concern
Solution Approach 1:
A heat dissipation plate is introduced as an intermediary component between the driver and the flange. This plate serves as a thermal conductor to transfer heat away from the driver, while the driver remains mounted on the flange upper surface with minimized wire length to the fuel pump module.
Solution Approach 2:
The heat dissipation plate is positioned to replicate the driver's thermal footprint, creating an extended thermal management interface with the flange. This allows efficient heat transfer across a larger surface area without changing the driver's mounting location.
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
This configuration eliminates spatial installation constraints, reduces voltage drop-related performance issues, and simplifies production by integrating the driver directly into the module, enhancing operational efficiency and heat dissipation.
Implementation Method 1
a heat-dissipating protective cap made of aluminum or stainless steel
Data Source
AI summary
Provided is a driver-integrated type BLDC fuel pump module, which is used in a vehicle and in which a driver used for controlling the operation of a BLDC fuel pump is installed in a flange of the BLDC fuel pump module, thus removing the spatial limit caused when the driver is installed and reducing the length of an electric wire electrically connecting the driver to a BLDC fuel pump of the module, thereby solving the problem of the operational performance of the BLDC fuel pump deteriorating as a result of both the voltage drop in the electric wire and a reduction in the operational efficiency of the pump.