Integrated Gerotor Pump Rotor and Motor Design
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Solution Overview
Problem
Existing gerotor pumps face challenges in assembly and material compatibility, particularly when transitioning from metal to plastic housing components, requiring precise tolerances and complex bearing arrangements due to the long rotating shaft and the need for sealing the electric motor and pump components.
Innovation Solution
A gerotor pump design where the outer gerotor is integrally formed with the electric motor rotor, with magnets embedded, allowing direct drive from the rotor to the outer gerotor and reducing the shaft's duties to centering and support, enabling simpler assembly and using a bell-shaped housing lid with a molded stator for fluid operation, and bayonet connections for assembly components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the shaft is made long to rotate both the electric motor and pump components, then the drive function is achieved, but the manufacturing precision and assembly difficulty increase
Solution Approach 1:
The patent merges the electric motor rotor and pump outer gerotor into a single integrated component. This eliminates the need for a long shaft to connect separate motor and pump elements, thereby reducing manufacturing tolerance requirements and simplifying assembly while maintaining the drive function.
Solution Approach 2:
The integrated rotor-gerotor component serves multiple functions simultaneously: it acts as both the motor rotor and the pump's outer gerotor. This multi-functionality eliminates the need for separate drive shafts and reduces the number of components requiring precise tolerances.
2Strength
If metal housing components are used, then structural integrity is achieved, but the complexity of assembly and sealing increases
Solution Approach 1:
The patent employs composite material construction, particularly using plastic for the housing base and integrating metal components only where necessary for strength and magnetic properties. This reduces overall assembly complexity while maintaining required structural integrity through strategic material selection.
Solution Approach 2:
The housing base is designed to integrate multiple functions: it serves as both the pump housing and the electric motor housing, eliminating the need for separate housing components and their associated sealing requirements. This merging reduces assembly complexity while maintaining structural strength.
3Ease of manufacture
If separate housing components are used for motor and pump, then manufacturing flexibility is achieved, but the number of sealing interfaces and assembly steps increases
Solution Approach 1:
The patent merges the motor housing and pump housing into a single integrated housing base. This eliminates the sealing interface that would exist between separate motor and pump housings, thereby reducing the number of sealing interfaces and assembly steps while maintaining manufacturing flexibility through modular component design.
4Reliability
If the shaft is exposed on both sides for mounting, then the support function is achieved, but the bearing arrangement complexity increases
Solution Approach 1:
The patent extracts the shaft from its traditional dual-sided mounting configuration and reduces it to a single-sided exposed shaft. The shaft is now only exposed on one end for component mounting, while the other end is integrated into the housing, thereby simplifying the bearing arrangement while maintaining the support function.
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
Simplifies the assembly process, reduces the risk of flow issues in plastic housing parts, and allows operation in fluid environments without additional sealing, while maintaining structural integrity and reducing assembly complexity.
Implementation Method 1
the electric motor comprises a stator as well as a rotor with permanent magnets
Implementation Method 2
the rotor with permanent magnets
Data Source
AI summary
Gerotor pump comprising an inner gerotor and an outer gerotor and an electric motor in a pump housing, and the outer gerotor is formed integrally with the rotor of the electric motor, wherein magnets are integrated into the outer gerotor, and the rotor is rotatably mounted on a shaft that is fixed on one side to a housing or a housing base of the pump housing.