Integrated Rotor Group for Vehicle Cooling Pump Assembly
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Solution Overview
Problem
Existing cooling pumps for vehicles are complex, expensive, and prone to malfunctions due to multiple components requiring intricate manufacturing and assembly processes, leading to a short lifespan.
Innovation Solution
A simplified rotor group for cooling pumps with a reduced number of components, manufactured using a single-piece molding process, where a shaft and rotor are integrated with a magnetically sensitive insert and a polymeric main device for efficient electromagnetic actuation, and a production method involving a heated mold for controlled material injection and solidification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple components (impeller, rotation shaft, electric motor group) are used to achieve cooling pump function, then the cooling pump can move cooling liquid towards predefined components, but the manufacturing operations and assembly steps become complex
Solution Approach 1:
The patent merges the impeller, rotation shaft, and electric motor group into a single integrated rotor body component. The rotor body includes an impeller portion with cooling liquid moving means, a rotation shaft portion, and a motor portion with electromagnetic actuation means, all formed as one piece through injection molding. This eliminates the need for separate components and complex assembly steps while maintaining the cooling pump's functional reliability.
2Ease of manufacture
If multiple components with complex manufacturing operations are used, then the cooling pump can be manufactured with specific functions, but the production cost increases
Solution Approach 1:
The rotor body is manufactured as a single integrated component through injection molding, combining what would traditionally require separate manufacturing processes for the impeller, shaft, and motor. This single-step manufacturing approach eliminates multiple assembly operations and reduces production complexity while maintaining all necessary functions.
Solution Approach 2:
The patent uses a two-shot injection molding process where different materials are injected in sequence - first a polyamide material for the motor portion and shaft, then a polypropylene material for the impeller portion. This parameter change in material injection enables complex multi-material functionality in a single manufacturing step.
3Manufacturing precision
If traditional multi-component cooling pumps are manufactured to meet high quality standards, then the components can function reliably, but the manufacturing process becomes particularly complex
Solution Approach 1:
The patent employs a two-shot injection molding process that automatically ensures precise interfaces between different materials (polyamide and polypropylene) within the rotor body. The sequential injection of different materials with controlled parameters achieves high manufacturing precision for the integrated component without requiring complex post-assembly operations.
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 solution results in a more reliable, cost-effective, and compact cooling pump with reduced assembly complexity, improved durability, and efficient liquid circulation, while minimizing space requirements in the vehicle engine compartment.
Implementation Method 1
the rotor (3) is suitable to be actuated in rotation by a stator (930) through electronic control means (931)
Data Source
Figure 1
Figure 1'
Figure 2~2'
AI summary
Rotor group (1) of a cooling pump (900) of a cooling circuit of a vehicle. The rotor group (1) comprises a shaft (2) and a rotor (3) fixed to the shaft (2); wherein the rotor (3) comprises a rotor frame (30) having a plurality of polar cavities (310) accommodating a plurality of inserts (31). The rotor group (1) comprises a main device (5) that comprises a rotor body (53) that extends from the shaft (2) and surrounds the rotor (3) suitable to integrally support the rotor (3) at the shaft. The main device (5) also comprises an impeller body (54) that extends radially from the shaft (2) at an end of the shaft (2) opposite the rotor (3).