Integrated Motor-Pump Assembly With Shared Cooling and Control
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Solution Overview
Problem
Existing electric motor and hydraulic pump systems are often separate entities with multiple controllers, leading to inefficiencies, mechanical wear due to cavitation, and separate cooling systems, which increase complexity and cost.
Innovation Solution
An integrated assembly that combines an electric motor, hydraulic pump, and electronic drive device within a single housing, sharing components, reducing cavitation through dual support of the rotor, and using pump fluid for cooling, with a cooling circuit and integrated sensor system for enhanced control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If electric motor and hydraulic pump are separate entities with multiple controllers, then system functionality is achieved, but system complexity and cost increase
Solution Approach 1:
The patent combines the electric motor, hydraulic pump, and electronic drive device into a single integrated assembly. The motor rotor serves dual purposes as both the motor rotor and the hydraulic pump rotor, sharing common components such as the rotor housing, bearing supports, and cooling circuits. This merging reduces the number of separate controllers and interconnections, thereby reducing system complexity while maintaining functionality.
Solution Approach 2:
The motor rotor is designed to serve multiple functions: it acts as the rotor for the electric motor and simultaneously as the rotor for the hydraulic pump. The rotor housing serves both as the motor rotor housing and as the hydraulic pump housing. This multi-functionality eliminates the need for separate components and controllers, reducing overall system complexity.
2Device complexity
If separate cooling systems are used for motor and pump, then cooling effectiveness is maintained, but system complexity increases
Solution Approach 1:
The patent integrates the cooling circuits for both the electric motor and the hydraulic pump into a single shared cooling system. The cooling channels are formed in the rotor housing, which serves both components. This shared cooling circuit reduces system complexity by eliminating redundant cooling systems while effectively managing the temperature of both the motor and pump components.
3Device complexity
If multiple controllers are used for motor and pump control, then control functionality is achieved, but control system complexity increases
Solution Approach 1:
The patent integrates the electronic drive device controller into the motor controller, eliminating the need for separate pump controllers. The motor controller receives sensor information from both the motor and the hydraulic pump and processes control signals for both components. This integration simplifies the control system by reducing the number of controllers and interconnections, making the system easier to operate.
4Volume of moving object
If hydraulic pump is positioned within motor rotor, then space efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent positions the hydraulic pump within the motor rotor, with the pump rotor housed inside the motor rotor housing. This nested arrangement maximizes space efficiency by utilizing the internal volume of the motor rotor for the hydraulic pump components. The dual-support bearing configuration and integrated cooling circuits are designed to accommodate this nested layout, making the manufacturing process manageable despite the complex geometry.
5Reliability
If dual support for motor rotor is implemented, then cavitation is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent implements dual support for the motor rotor by positioning bearing supports at both ends of the rotor housing. This dual-support configuration prevents rotor deflection and misalignment, thereby reducing cavitation in the hydraulic pump. The bearing supports are integrated into the rotor housing structure, which simplifies the manufacturing process by combining multiple functions into a single component.
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 integrated system reduces mechanical wear, enhances reliability, saves space, and lowers costs by sharing components, while providing efficient control and cooling, thus improving overall system performance.
Implementation Method 1
a plurality of cooling fluid channels formed in the main housing and configured to allow fluid to circulate through the main housing to cool the main housing
Implementation Method 2
using pump fluid for cooling, with a cooling circuit
Data Source
AI summary
An example assembly includes a main housing having an internal chamber therein; an electric motor disposed in the internal chamber of the main housing and comprising (i) a stator that is fixedly-positioned in the internal chamber of the main housing, and (ii) a motor rotor positioned within the stator and rotatable relative to the stator; a hydraulic pump positioned in the main housing, at least partially within the motor rotor of the electric motor, wherein the hydraulic pump is configured to receive fluid from an inlet port and provide fluid flow to an outlet port, wherein the hydraulic pump comprises a pump drive shaft rotatably-coupled to the motor rotor of the electric motor; and a plurality of cooling fluid channels formed in the main housing and configured to allow fluid to circulate through the main housing to cool the main housing.