Fuel Pump Motor Stator Segmented Passage Design
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Solution Overview
Problem
Existing fuel pumps with brushless motors face a trade-off between achieving sufficient fuel delivery quantity and maintaining magnetic efficiency, as increasing the fuel passage cross-sectional area reduces magnetic force, while reducing the gap increases flow resistance, making it difficult to achieve both high efficiency and required fuel delivery in compact designs.
Innovation Solution
A fuel pump design with a stator core having six magnetic steel plates and a rotor with eight magnetic poles, using dielectric resin to create clearances between teeth for increased passage area without reducing magnetic force, and employing a concentrated winding technique to minimize coil size and maximize space factor, allowing for efficient fuel flow through the motor arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the gap between stator and rotor is increased to create sufficient passage cross-sectional area for fuel flow, then fuel delivery quantity is improved, but magnetic force between rotor and stator is reduced, worsening motor efficiency
Solution Approach 1:
The fuel passage is segmented into two distinct paths: the gap between stator and rotor for fuel flow, and clearances formed between circumferentially adjacent teeth on the rotor side for additional fuel passage. This segmentation allows sufficient fuel delivery area without increasing the gap size that would reduce magnetic force.
Solution Approach 2:
Instead of increasing the radial gap dimension, the invention utilizes the circumferential dimension by forming clearances between adjacent teeth. This dimensional shift provides additional passage area without compromising the magnetic coupling between stator and rotor.
2Loss of energy
If the gap between stator and rotor is reduced to increase magnetic force, then motor efficiency is improved, but passage cross-sectional area is reduced, increasing flow resistance and worsening fuel delivery
Solution Approach 1:
The fuel passage is segmented into two distinct paths: the gap between stator and rotor for fuel flow, and clearances formed between circumferentially adjacent teeth on the rotor side for additional fuel passage. This segmentation allows sufficient fuel delivery area without increasing the gap size that would reduce magnetic force.
Solution Approach 2:
The clearance between teeth provides localized additional passage area specifically in regions where it does not interfere with the magnetic field. This local quality enhancement allows increased fuel flow capacity without uniformly increasing the gap that would reduce magnetic force throughout.
3Device complexity
If coils are exposed to fuel for compact design, then device complexity is reduced, but coil reliability deteriorates due to fuel contact
Solution Approach 1:
Dielectric resin is used as an intermediary material that provides electrical insulation and fuel resistance between the coils and the fuel environment. This allows the coils to be positioned closer to the fuel passage without direct contact, maintaining both compact design and coil reliability.
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 the required fuel delivery quantity with minimized passage flow resistance and maintains magnetic efficiency, even with potential rotor swelling from fuel degradation, while allowing for a compact and efficient fuel pump suitable for small motorcycles.
Implementation Method 1
A bobbin, which is made of dielectric resin, is fitted to each core. Dielectric resin is filled between each circumferentially adjacent two teeth to cover each coil. Furthermore, the dielectric resin is molded to form clearances, each of which is formed between the corresponding circumferentially adjacent two teeth on a rotor side.
Implementation Method 2
a brushless motor to form a motor arrangement that drives a pump arrangement... In the brushless motor, there is no disadvantageous loss caused by a sliding resistance between a commutator and brushes
Implementation Method 3
A stator core of a motor arrangement includes six cores, which are arranged one after another in a circumferential direction... A rotor with eight magnetic poles
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
A stator core (30) of a motor arrangement (13) includes six cores (32), which are arranged one after another in a circumferential direction. A bobbin (40), which is made of dielectric resin, is fitted to each core (32). Each coil (42) is formed such that a winding is wound around the bobbin (40) through a concentrated winding technique. Dielectric resin (46) is filled between each circumferentially adjacent two teeth (33) to cover each coil (42). Furthermore, the dielectric resin (46) is molded to form clearances (204), each of which is formed between the corresponding circumferentially adjacent two teeth (33) on a rotor (50) side. Fuel, which is pressurized by a pump arrangement (12), passes an interior of the motor arrangement (13) through a fuel passage (202), which is a gap between an inner peripheral surface of the stator core (30) and an outer peripheral surface of the rotor (50), and also through the clearances (204).