Electric Coolant Pump Coil Carrier Positioning

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Solution Overview

Problem

Existing electric coolant pumps with canned motors face challenges in easy assembly and reliable electrical insulation of stator coils, particularly due to misalignment and conductivity issues during the assembly of coil carriers and motor electronics.

Innovation Solution

An electric coolant pump design featuring a plastic coil carrier with ferromagnetic stator laminations, a cylindrical plastic can body separating coolant and dry spaces, and axial line sleeves for precise electrical insulation and alignment, along with form-fitting and latching means for secure positioning, ensuring error-free assembly and insulation from conductive materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the coil carrier is pushed onto the can body during assembly, then the assembly process is simplified, but incorrect rotational and axial positioning may occur

Engineering Contradiction:

Improveassembly processVSAvoidrotational and axial positioning

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent employs asymmetric form-fitting means including a keyway on the coil carrier that fits into a corresponding key on the can body. This asymmetric feature ensures correct rotational positioning by preventing incorrect orientation of the coil carrier relative to the can body, while still allowing simple push-on assembly.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The coil carrier is designed to be nested onto the can body in a telescopic manner. The form-fitting means are integrated into the nested structure, allowing the coil carrier to be pushed onto the can body while maintaining precise rotational and axial positioning through the integrated positioning features.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If the coil lines are routed from stator coils to motor electronics, then electrical connection is established, but reliable electrical insulation and precise alignment become difficult to ensure

Engineering Contradiction:

Improveelectrical connectionVSAvoidalignment and insulation

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent introduces an axial line sleeve as an intermediary component that guides the coil lines from the stator coils to the motor electronics. This sleeve ensures precise alignment and provides electrical insulation, eliminating the need for complex routing while maintaining reliable electrical connection and insulation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The line sleeve acts as a flexible protective channel that accommodates the coil lines. It provides both mechanical guidance for precise alignment and electrical insulation, allowing the coil lines to be routed reliably without exposing them to conductive surfaces.

Inventive Principle:

Principle #30Flexible shells and thin films

3Strength

If the can body is made from electrically conductive material, then structural strength is improved, but electrical insulation of coil lines becomes problematic

Engineering Contradiction:

Improvestructural strengthVSAvoidelectrical insulation

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The axial line sleeve serves as an intermediary insulating barrier between the coil lines and the conductive can body. This allows the can body to be made from electrically conductive material for structural strength while the line sleeve provides the necessary electrical insulation for safe coil line routing.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 facilitates easy and error-free assembly, ensures reliable electrical insulation, and prevents misalignment, thereby enhancing the reliability and efficiency of the coolant pump's operation by maintaining precise alignment and secure fixation of components.

Implementation Method 1

The coil carrier can have a number of ferromagnetic stator laminations for concentrating the magnetic field generated by the stator coils

Methodology Applied

Scientific EffectFerromagnetism: Ferromagnetism

Implementation Method 2

at least one axial line sleeve is provided on the can body, through which one or more coil lines is/are electrically insulated and guided in a defined manner from the stator coils to the motor electronics

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Implementation Method 3

On the canned body and on the coil carrier mutually complementary form-fitting means are provided which ensure a clear rotational and axial positioning of the coil carrier in relation to the canned body

Methodology Applied

Scientific EffectMechanical interference fit: Mechanical Fastener

Data Source

PatentEP2738391B1Electric coolant pump

Publication Date: 2017.01.18 PIERBURG PUMP TECH

AI summary

The pump (10) has an inner-lying motor rotor (31) and outer-lying stator coils (32). A coil carrier (30) carries the stator coils, and a separate gap pipe body (40) comprises a coolant chamber (24) in which the motor rotor is arranged. The coolant chamber is separated from a drying chamber (26) in which the coil carrier is arranged. The pipe body has an elastic-snap-in pin, locking opening (50) and fixing opening for rotatable and axial positioning of the carrier at the pipe body. The pipe body or the carrier has an axial spacer casing for guiding a coil spacer. The pipe body is made from plastic.