Electromagnetic Forming for Brushless DC Motor Pump Housing Sealing
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Solution Overview
Problem
Conventional methods for manufacturing fluid pump assemblies with sensitive electronic circuitry for brushless DC motors are costly, complex, and prone to component damage, requiring additional fixturing and equipment contact, leading to increased cycle times and scrap rates.
Innovation Solution
The use of an electromagnetic forming device with an upper and lower fixture, along with a pneumatic or hydraulic actuation system, to seal the housing of the pump assembly without direct contact, utilizing a deformable conductive tubular member and an annular bead for sealing, while positioning the electronic control module to avoid magnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mechanical sealing methods (roll forming, mechanical crimping, fasteners, welding, adhesives) are used to seal the housing, then the housing can be sealed, but the manufacturing complexity increases, additional fixturing is required, and component damage occurs
Solution Approach 1:
The patent replaces conventional mechanical sealing methods (roll forming, mechanical crimping, fasteners, welding, adhesives) with electromagnetic forming technology. This substitution eliminates the need for complex mechanical fixturing and direct equipment contact with components, thereby reducing manufacturing complexity while maintaining seal integrity.
Solution Approach 2:
The patent introduces an electromagnetic field as an intermediary to achieve sealing. Instead of direct mechanical contact between equipment and components, the electromagnetic field acts as a mediator to deform and seal the housing, reducing component damage and equipment complexity.
2Reliability
If conventional mechanical sealing methods are used, then the housing can be sealed, but cycle times increase and scrap rates increase due to component damage
Solution Approach 1:
By replacing mechanical sealing systems with electromagnetic forming, the patent eliminates the need for multiple mechanical operations and complex fixturing, thereby reducing cycle times. The non-contact nature of electromagnetic forming also prevents component damage, reducing scrap rates.
3Reliability
If direct equipment contact is used for sealing, then the housing can be sealed, but component damage occurs and consistency decreases
Solution Approach 1:
The patent replaces direct mechanical contact with electromagnetic forming, which applies uniform force through the electromagnetic field. This eliminates variability introduced by mechanical contact points and fixturing, thereby improving sealing consistency while preventing component damage.
4Reliability
If additional fixturing and complex manufacturing facilities are used, then the housing can be sealed, but manufacturing costs increase
Solution Approach 1:
The patent replaces complex mechanical sealing facilities with electromagnetic forming equipment, which requires fewer mechanical components and fixturing. This substitution reduces manufacturing facility complexity and associated costs while maintaining seal integrity.
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 method reduces manufacturing complexity and costs, minimizes component damage, decreases cycle times, and enhances consistency and reduces scrap rates by eliminating direct equipment contact and optimizing the magnetic field to protect sensitive electronics.
Implementation Method 1
an electromagnetic forming device with an upper and lower fixture
Implementation Method 2
electromagnetic forming device is activated to seal the housing of the pump assembly
Data Source
Figure 1
Figure 2
AI summary
A system and method for manufacturing a brushless direct current (BLDC) motor fluid pump is disclosed. The system includes an electromagnetic forming device, an upper fixture, a lower fixture, and a pneumatic or hydraulic cylinder. The electromagnetic forming device has a central cavity. The central cavity has a predefined depth from an outer surface of the electromagnetic forming device. The upper fixture is disposed in the central cavity. The upper fixture has a pump stop surface that contacts the BLDC motor fuel pump, and the pump stop surface is selectively spaced from the outer surface of the electromagnetic forming device. A lower fixture having a central cavity for receiving the housing of the BLDC motor fluid pump is provided. A cylinder is configured to move the lower fixture towards the upper fixture until the pump stop surface of the upper fixture contacts the BLDC motor fluid pump. The electromagnetic forming device is activated to seal the housing of the pump assembly once the pump assembly is properly positioned within the magneforming device.