Canned Pump Hall Sensor Positioning via Form-Fit Intermediary
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Solution Overview
Problem
Existing coolant pumps face challenges in precisely and reproducibly positioning Hall sensors for motor rotor detection, especially in difficult-to-access areas, which can affect electronic commutation and lead to vibrations and inaccuracies.
Innovation Solution
An electric canned coolant pump design featuring a Hall sensor with rigid connecting lines and an electrically insulating connecting body, integrated form-fit structures on the separating can, and radial guide webs for precise positioning and vibration tolerance, allowing for a simple, cost-effective, and accurate assembly and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the Hall sensor is positioned in difficult-to-access areas on the separating can, then the motor rotor position detection is improved, but the sensor positioning precision and reproducibility deteriorate
Solution Approach 1:
The patent introduces a positioning element as an intermediary component between the Hall sensor and the separating can. This positioning element features a form-fit structure that engages with corresponding structures on the separating can, enabling precise and reproducible positioning of the Hall sensor even in difficult-to-access areas. The positioning element acts as a mediator that translates the complex positioning requirements into a simple assembly process.
2Measurement precision
If the Hall sensor is positioned close to the motor rotor for accurate detection, then the position detection accuracy is improved, but the sensor becomes more susceptible to vibrations and positional deviations
Solution Approach 1:
The patent segments the Hall sensor assembly into distinct functional components: the Hall sensor itself, the positioning element with form-fit structures, and the connecting body. This segmentation allows the positioning element to specifically address vibration and positional stability requirements through its rigid form-fit structures, while the Hall sensor maintains its optimal positioning for accurate motor rotor detection.
Solution Approach 2:
The positioning element with its form-fit structure provides beforehand cushioning against vibrations and positional deviations. The rigid connecting body and form-fit engagement with the separating can create a stable mounting structure that prevents vibrations and positional shifts before they can affect the Hall sensor's measurement accuracy.
3Manufacturing precision
If a complex positioning mechanism is used to achieve precise Hall sensor positioning, then the positioning precision is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple functions into the positioning element: positioning, mechanical support, and electrical connection protection. The form-fit structure combines positioning and mounting functions, while the rigid connecting body integrates support and protection of electric connecting lines. This merging reduces device complexity compared to using separate components for each function.
Solution Approach 2:
The positioning element serves multiple purposes: it positions the Hall sensor with high precision, provides mechanical support, protects the electric connecting lines, and ensures reproducible assembly. This multi-functionality reduces the overall number of components needed and simplifies the manufacturing process while maintaining high positioning precision.
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 design ensures high precision and reliability in motor rotor position detection, enhancing commutation quality, reducing power surges, and enabling a lower power design for the drive motor while maintaining operational safety.
Implementation Method 1
A Hall sensor is provided in the dry chamber at the separating can to detect the rotary position of the motor rotor for the purpose of electronic commutation
Data Source
AI summary
An electric canned coolant pump includes a drive motor comprising a split case provided as a separating can which separates a wet chamber comprising a motor rotor from a dry chamber comprising a motor stator. The separating can comprises a separating can form-fit structure. A Hall sensor is arranged on the separating can. The Hall sensor detects a position of the motor rotor in the dry chamber. The Hall sensor comprises a sensor head and Hall sensor electric connecting lines. A positioning element comprises positioning element electric connecting lines which are connected with the corresponding Hall sensor electric connecting lines. The positioning element electric connecting lines comprise a connecting body comprising a connecting body form-fit structure. The connecting body is electrically insulating and holds the positioning element electric connecting lines. The separating can form-fit structure and the connecting body form-fit structure fix the connecting body on the separating can.